CN111136996B

CN111136996B - System and method for simultaneously laminating and finishing composite laminates

Info

Publication number: CN111136996B
Application number: CN201911021778.XA
Authority: CN
Inventors: A·E·莫丁; D·D·琼斯; K·S·威尔登
Original assignee: Boeing Co
Current assignee: Boeing Co
Priority date: 2018-11-01
Filing date: 2019-10-25
Publication date: 2022-11-04
Anticipated expiration: 2039-10-25
Also published as: CA3053492A1; CA3053492C; EP3647030A1; CN111136996A; US20200139649A1; EP3647030B1; JP7373355B2; JP2020097221A

Abstract

The present invention relates to a system and method for simultaneously laminating and finishing a composite laminate. The manufacturing system includes a plurality of laminating heads stationarily positioned in end-to-end relationship with one another and defining a laminating station and configured to dispense paving material along a dispensing direction. The manufacturing system also includes a laminating surface movable below the laminating station. The lamination head is configured to sequentially apply a layup material onto the lamination surface and onto a previously applied layup material as the lamination surface passes through the lamination station, thereby forming a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by the positions of the lamination heads relative to each other within the lamination station. The manufacturing system also includes one or more finishing devices configured to finish the composite laminate.

Description

System and method for simultaneously laminating and finishing composite laminates

Technical Field

The present disclosure relates generally to manufacturing systems and, more particularly, to systems and methods for simultaneously laminating and finishing composite laminates.

Background

Composite materials are used in a variety of applications due to their advantageous properties such as high specific strength, high specific stiffness and high corrosion resistance. The manufacture of composite structures typically involves laying up a plurality of plies of composite laminate material onto a mandrel to form a composite laminate. The paving material is typically a fibrous material (e.g., prepreg) pre-impregnated with resin. For example, the layup material may be an epoxy impregnated carbon fiber prepreg.

Current methods of laying up composite laminates include ply-by-ply lamination, in which a single lamination head makes multiple passes (pass) over a lamination mandrel. During each pass, the lamination head applies a single ply of paving material. At the end of each pass, the lamination head may return to the beginning of the most recently applied ply and apply another sheet of paving material over the most recently applied ply. This process is repeated until the composite laminate has the desired number of plies and ply stacking order. It will be appreciated that the continuous application of a single sheet of paving material limits the rate at which a composite laminate can be manufactured. Further limiting the rate of manufacture, it is conventional practice to trim the composite laminate as a separate post-processing step performed after lamination.

It can be seen that there exists a need in the art for a system and method for manufacturing a composite laminate that avoids the above-described limitations associated with ply-by-ply lamination and trimming as a separate step.

Disclosure of Invention

The above-described needs associated with manufacturing composite laminates are specifically addressed and alleviated by the present disclosure which provides a manufacturing system having a plurality of lamination heads stationarily positioned in end-to-end relationship with each other and defining a lamination station. Each lamination head is configured to dispense paving material along a dispensing direction. The manufacturing system includes a lamination surface movable between a lamination surface home position and a lamination surface rear position in a direction generally aligned with the dispensing direction below the lamination station. The lamination head is configured to sequentially apply a layup material onto the lamination surface and onto a previously applied layup material as the lamination surface passes through the lamination station, thereby forming a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by the position of the lamination head relative to each other within the lamination station. The manufacturing system also includes one or more finishing devices located proximate at least one of the opposite ends of the laminating station. The finishing device is configured to finish the composite laminate during movement of the lamination surface from the lamination station to the lamination surface home position and/or during movement of the lamination surface from the lamination station to the lamination surface aft position.

In another embodiment, a manufacturing system is disclosed having a series of lamination heads stationarily positioned in end-to-end relationship with each other and defining a lamination station. Each lamination head within the series is configured to dispense paving material along a dispensing direction. The manufacturing system also includes a laminating belt having an outer surface movable below the laminating station in a direction generally aligned with the dispensing direction. The lamination head is configured to sequentially apply a layup material onto the outer surface of the lamination belt and onto a previously applied layup material as the outer surface of the lamination belt moves through the lamination station, thereby forming a stacked composite laminate having composite plies arranged in a desired ply stacking order defined by the positions of the lamination heads relative to each other within the lamination station. The manufacturing system also includes one or more finishing devices located downstream of the lamination station and configured to periodically form transverse cuts in the composite laminate to separate the composite laminate into longitudinal segments.

A method of manufacturing a composite laminate is also disclosed. The method includes dispensing paving material in a dispensing direction from one or more of a series of laminating heads stationarily positioned in end-to-end relationship with one another and defining a laminating station. The method includes moving the laminating surface between a laminating surface home position and a laminating surface back position in a direction generally aligned with the dispensing direction below the laminating station. Further, the method includes applying a layup material from one or more layup heads onto the lamination surface and onto the previously applied layup material as the lamination surface passes through the lamination station, thereby forming a composite laminate having a stack of composite plies arranged in a desired ply stacking order. A lamination head is arranged within the series of lamination heads to sequentially apply the layup material according to a ply stacking order. The method further includes trimming the composite laminate using one or more trimming devices during movement of the lamination surface from the lamination station to the lamination surface home position and/or during movement of the lamination surface from the lamination station to the lamination surface aft position.

The features, functions, and advantages that have been discussed can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.

Drawings

These and other features of the present disclosure will become more apparent with reference to the accompanying drawings, wherein like reference numerals refer to like parts throughout, and wherein:

FIG. 1 is a side view of an embodiment having a manufacturing system with a fixed lamination station including a series of lamination heads and having one or more finishing devices to simultaneously laminate and finish a composite laminate;

FIG. 2 is a top view of the manufacturing system of FIG. 1;

FIG. 3 is an enlarged view of the encircled area identified by reference numeral 3 of FIG. 1 and showing each lamination head supported by the support frame and also showing the lamination surface configured as at least one lamination mandrel that is movable below the lamination station and receives a layup material applied by one or more of the series of lamination heads;

FIG. 4 is a side view of a portion of the manufacturing system of FIG. 3 showing a lamination mandrel passing under the series of lamination heads;

FIG. 5 is a side view of an embodiment of a manufacturing system in which a laminating surface is configured as one or more laminating belts;

FIG. 6 is a perspective view of an embodiment of a series of laminating heads that apply a paving material to a laminating surface moving beneath the laminating heads;

FIG. 7 is a side view of an embodiment of a laminating head applying a paving material to a laminating surface;

FIG. 8 is a table listing the material configurations of paving material dispensed by each of the 10 laminating heads in the laminating station;

FIG. 9 is a cross-sectional view of the composite laminate having a ply stacking sequence resulting from the sequential application of the layup materials dispensed by the lamination heads listed in FIG. 8 taken along line 9 of FIG. 6;

FIG. 10 is a schematic view of a series of laminating heads applying a layup material to a laminating mandrel at a first point in time during movement of the laminating mandrel through a laminating station;

fig. 11 is a schematic view of the series of lamination heads of fig. 10 at a second point in time during movement of the lamination mandrel through the lamination station, and showing the creation of a gap in the ply 2 due to the temporary stop and restart of head No. 2;

FIG. 12 is a cross-sectional view of an embodiment of a composite laminate wherein the layup material dispensed by the lamination head has different material widths resulting in opposite side edges of the composite laminate being formed at oblique angles;

FIG. 13 is a cross-sectional view of an embodiment of a composite laminate wherein a reduced number of 10 lamination heads dispense paving material resulting in a composite laminate having a reduced thickness and a lower bevel angle than the composite laminate shown in FIG. 12;

FIG. 14 is an end view of an embodiment of the manufacturing system taken along line 13 of FIG. 3 and illustrating a support frame supporting the lamination head;

FIG. 15 is an end view of an embodiment of the manufacturing system taken along line 14 of FIG. 3 and showing a support frame supporting a finishing assembly;

FIG. 16 is a top view of a portion of a laminating station of the manufacturing system, wherein the laminating heads each have a first side and a second side, each configured to dispense a layup material, and showing one of the laminating heads laterally translated out of alignment with the series of laminating heads to allow replacement of a depleted roll of material on the first side of the laminating head;

FIG. 17 is a top view of the laminating station of FIG. 16, showing the laminating head rotated 180 degrees about a vertical axis such that the second side of the laminating head is rotated to the position previously occupied by the first side of the laminating head;

FIG. 18 is a top view of the laminating station of FIG. 17, showing the laminating head translated back into alignment with the series of laminating heads to allow the second side of the laminating heads to dispense paving material;

FIG. 19 is a top view of the laminating station of FIG. 18, showing a roll of replacement material mounted on a first side of the laminating head;

FIG. 20 is an end view of an embodiment of a manufacturing system configured to allow vertical translation of one or more lamination heads out of alignment with the series of lamination heads;

figure 21 shows one of the lamination heads of figure 20 after vertical translation allows the lamination head to rotate about a vertical axis by an amount of 180 degrees as a means of rotating the second side of the lamination head to the position previously occupied by the first side of the lamination head;

FIG. 22 is a top view of another embodiment of a laminating system, wherein the series of laminating heads are supported on a horizontal axis configured to allow each laminating head to independently rotate 180 degrees about the horizontal axis to rotate the second side of each laminating head to the position previously occupied by the first side of the laminating head to allow the second side to dispense paving material;

FIG. 23 is a side view of the laminating system of FIG. 22;

FIG. 24 is a cross-sectional view taken along line 24 of FIG. 23, showing one of the lamination heads supported on a horizontal axis;

FIG. 25 is a cross-sectional view taken along line 25 of FIG. 23, showing one of a pair of opposing axle supports configured to support a horizontal axle;

figure 26 is a cross-sectional view of the laminating system of figures 22-23, showing the horizontal axis and the series of laminating heads translated vertically upward to provide clearance for the laminating mandrel to allow the laminating heads to rotate with the material supply drum depleted on a first side of the laminating heads;

FIG. 27 is a cross-sectional view of the laminating system of FIG. 26, showing rotation of one of the laminating heads to rotate the second side of the laminating head to the position previously occupied by the first side of the laminating head;

FIG. 28 is a cross-sectional view of the laminating system of FIG. 27, showing the horizontal axis and the series of laminating heads translated vertically downward to allow a second side of the laminating heads to dispense paving material;

fig. 29 is a perspective view of an embodiment of a laminated head having a mounting frame and a head module that can be removably coupled to each of opposite sides of the mounting frame, and wherein each head module is independently vertically movable on the mounting frame;

FIG. 30 is a top view of a portion of a lamination station of the manufacturing system with each lamination head of the series of lamination heads having a removable head module and showing one of the lamination heads translated laterally out of alignment with the series of lamination heads to allow replacement of the head module;

FIG. 31 is a top view of the laminating station of FIG. 30, showing the laminating head rotated 180 degrees about a vertical axis such that the head module faces away from the series of laminating heads;

FIG. 32 is a top view of the laminating station of FIG. 31, showing the head module with the depleted roll replaced with a head module with a new roll;

FIG. 33 is a top view of the laminating station of FIG. 32, showing the laminating head translated back into alignment with the series of laminating heads;

FIG. 34 is a side view of an embodiment of a manufacturing system having a reloading system for automatically replacing lamination heads in a series;

FIG. 35 is a top view of the manufacturing system of FIG. 34;

FIG. 36 is a sectional view taken along line 36 of FIG. 35 and illustrates an embodiment of a head holder configured to support a replacement lamination head;

FIG. 37 is a sectional view taken along line 37 of FIG. 35 and illustrating an embodiment of a head transport mechanism configured to remove and replace any one lamination head with a replacement lamination head;

FIG. 38 is a cross-sectional view of the manufacturing system of FIGS. 34-35 showing a head transport mechanism engaging one of the lamination heads in the lamination head;

FIG. 39 is a cross-sectional view of the manufacturing system of FIG. 38, showing the head transport mechanism translating the lamination head vertically upward to the level of the head holder;

FIG. 40 is a side view of an embodiment of a manufacturing system in which the series of lamination heads includes a series of head modules removably attached to a single head support beam;

FIG. 41 is a top view of an embodiment of a manufacturing system showing a lamination mandrel in a lamination surface home position during an initial stage of manufacturing a composite laminate, the initial stage including laminating the composite laminate while the lamination mandrel is moving through a lamination station in a first direction of travel;

FIG. 42 is a top view of the manufacturing system of FIG. 41 showing simultaneous lamination and trimming of the composite laminate as the lamination mandrel moves in a first direction of travel through the lamination station and through the trimming station toward a lamination surface back position;

FIG. 43 is a top view of the manufacturing system of FIG. 42, showing the lamination mandrel in a position aft of the lamination surfaces, and showing the composite laminate in a trimmed state;

FIG. 44 is a top view of the manufacturing system of FIG. 43, showing the lamination mandrel after moving back in a second direction of travel toward the lamination surface home position prior to laterally translating to the lamination surface unload position;

FIG. 45 is a top view of an embodiment of the manufacturing system showing the lamination mandrel in a lamination surface home position during an initial stage of manufacturing the composite laminate, the initial stage including laminating the composite laminate as the lamination mandrel moves through the lamination station in the second direction of travel;

FIG. 46 is a top view of the manufacturing system of FIG. 45, showing a lamination mandrel in a lamination surface back position and supporting the composite laminate in an untrimmed condition;

FIG. 47 is a top view of the manufacturing system of FIG. 46 showing the lamination mandrel moving back in a second direction of travel from the lamination station through the finishing station toward the lamination surface home position;

FIG. 48 is a top view of the manufacturing system of FIG. 47, showing a lamination mandrel in a lamination surface unloading position and supporting the composite laminate in a trimmed state;

FIG. 49 is an end view of an embodiment of one or more lamination mandrels moving horizontally between a lamination surface preparation position, a lamination surface home position, and a lamination surface unload position;

FIG. 50 is an end view of an embodiment of one or more lamination mandrels vertically moved between a lamination surface preparation position and a lamination surface home position;

FIG. 51 is a top view of an embodiment of a manufacturing system showing a lamination mandrel in a lamination surface home position during an initial stage of manufacturing a composite laminate that includes simultaneous lamination and trimming of the composite laminate during movement of the lamination mandrel in a first direction of travel, followed by movement of the lamination mandrel back to the lamination mandrel home position and bypassing of a lamination station;

FIG. 52 is a top view of the manufacturing system of FIG. 51 showing the lamination mandrel moving in a first direction of travel through the lamination station and the trimming station toward a lamination surface rear position;

FIG. 53 is a top view of the manufacturing system of FIG. 52 showing a lamination mandrel in a post lamination surface position and supporting the composite laminate in a trimmed condition;

FIG. 54 is a top view of the manufacturing system of FIG. 53 after the lamination mandrel has been moved back to the lamination mandrel home position and has passed around the lamination station;

FIG. 55 is a top view of an embodiment of the manufacturing system showing the lamination mandrel in a lamination surface home position during an initial stage of manufacturing the composite laminate, which includes simultaneous lamination and trimming of the composite laminate during movement of the lamination mandrel around the lamination station toward a post position of the lamination station, followed by movement of the lamination mandrel in a second direction of travel for simultaneous lamination and trimming of the composite laminate;

FIG. 56 is a top view of the manufacturing system of FIG. 55, showing the lamination mandrel in a position aft of the lamination surface;

FIG. 57 is a top view of the manufacturing system of FIG. 56, illustrating simultaneous lamination and trimming of the composite laminate during movement of the lamination mandrel in the second direction of travel through the lamination station and the trimming station;

FIG. 58 is a top view of the manufacturing system of FIG. 57, showing a lamination mandrel in a lamination surface home position and supporting the composite laminate in a trimmed condition;

FIG. 59 is a top view of an embodiment of the manufacturing system in an initial stage of continuously laying up composite laminates on an end-to-end series of lamination mandrels continuously movable through a lamination station;

FIG. 60 is a top view of the manufacturing system of FIG. 59, showing laying up the composite laminate on the series of lamination mandrels, and further showing a trimming device forming transverse cuts in the composite laminate to separate the composite laminate into end-to-end longitudinal segments;

FIG. 61 is a top view of the manufacturing system of FIG. 59 showing one of the lamination mandrels in a position aft of the lamination surface and showing in phantom a longitudinal section of the composite laminate after unloading from the lamination mandrel;

FIG. 62 is a side view of the manufacturing system of FIG. 61 showing the successive layup of composite laminates on the series of lamination mandrels moving end-to-end through the lamination station;

FIG. 63 is a top view of an embodiment of the manufacturing system in an initial stage of continuously laying up a composite laminate on a continuous endless laminating belt;

FIG. 64 is a top view of the manufacturing system of FIG. 63, illustrating continuous layup of the composite laminate, and further illustrating a trimming device forming transverse cuts in the composite laminate to separate the composite laminate into end-to-end longitudinal segments;

FIG. 65 is a top view of the manufacturing system of FIG. 64 showing in phantom a longitudinal section of the composite laminate after being unloaded from the laminate strip;

FIG. 66 is a side view of the manufacturing system of FIG. 65, showing continuous laying of composite laminates on a laminate strip;

FIG. 67 is a flow chart of operations included in a method of manufacturing a composite laminate.

Detailed Description

Referring now to the drawings, which illustrate various preferred embodiments of the present disclosure, a side view of an embodiment of the presently disclosed manufacturing system 100 for manufacturing an uncured composite laminate 400 is shown in FIG. 1. Fig. 2 is a top view of the manufacturing system 100. The manufacturing system 100 has a fixed laminating station 150 and a movable laminating surface 120. The laminating station 150 has a plurality of laminating heads 152, each laminating head 152 configured to dispense a layup material 228. The plurality of laminating heads 152 are configured to sequentially apply a paving material 228 onto the laminating surface 120 and onto previously applied paving material 228 during at least one pass across the laminating surface 120 of the laminating station 150. Although the figures show the laminating heads 152 being identically configured, the laminating station 150 may include one or more different types of laminating heads 152.

The lamination heads 152 are arranged in end-to-end relationship with one another (fig. 6) to form at least one series of lamination heads 152. As the lamination surface 120 passes under the lamination head 152, the lamination head 152 collectively dispenses a plurality of plies 402 (fig. 9) of the layup material 228 (fig. 9) to batch laminate the composite laminate 400 according to a desired ply stacking sequence 410 (e.g., fig. 8-9). In this regard, each lamination head 152 in the series is dispensed with a layup material 228 having a material configuration 406 (fig. 8) corresponding to the ply stacking sequence 410 of composite laminate 400. The ply stacking sequence 410 is defined by the relative position of the lamination head 152 within the lamination station 150, as described in more detail below. Additionally, manufacturing system 100 has one or more finishing devices 312 located within one or more finishing stations 310 to finish composite laminate 400. Trimming of composite laminate 400 may be performed simultaneously with lamination of composite laminate 400, as described below.

Advantageously, the batch lamination of composite laminates 400 onto a moving lamination surface 120 by a plurality of end-to-end lamination heads 152 in the presently disclosed manufacturing system 100 enables higher manufacturing rates than can be achieved with conventional methods of layer-by-layer lamination using lamination heads 152 that make multiple passes over the lamination surface. Moreover, trimming composite laminate 400 while laminating composite laminate 400 further increases the manufacturing rate over that which can be achieved using conventional practice of trimming composite laminate 400 as separate steps performed at different locations.

Referring to fig. 1-4, a manufacturing system 100 may include a base member 102 supported on a surface, such as a factory floor. The base member 102 may include a lamination surface origin location 134 on one end of the lamination station 150 and a lamination surface back location 136 on the opposite end of the lamination station 150. The laminating surface 120 may be supported on the base member 102. For example, the lamination surface 120 can be an outer surface of at least one lamination mandrel 122 (e.g., fig. 1-4), the lamination mandrel 122 being movable or slidable along a longitudinal rail 140, the longitudinal rail 140 extending along a length of the base member 102. The lamination mandrel 122 may be moved via a linear translation mechanism (not shown), such as a screw drive coupled to a drive motor. Alternatively, one or more lamination mandrels 122 may be manually moved between the lamination surface home position 134, the lamination station 150, and the lamination surface back position 136. In yet another embodiment, one or more lamination spindles 122 may be moved between the lamination surface home position 134, the lamination station 150, and the lamination surface back position 136 using an autonomous vehicle (not shown) that is not on track or by using one or more robotic devices (not shown).

Although fig. 1-4 illustrate a single lamination mandrel 122 moving through the lamination station 150, in embodiments a manufacturing system 100 may be provided in which a series of end-to-end lamination mandrels 122 are continuously moved through the lamination station 150 to enable continuous dispensing of the layup material 228 by the lamination head 152 to individually lay up the composite laminate 400 on each of the series of lamination mandrels 122. The series of lamination mandrels 122 may be arranged in an end-to-end relationship spaced apart from one another (e.g., up to several inches), or the series of lamination mandrels 122 may be arranged in an end-to-end relationship abutting one another. Alternatively, such a manufacturing system 100 may be provided in one embodiment wherein a continuous composite laminate 400 is laid up on a series of butted, end-to-end lamination mandrels 122, and the composite laminate 400 may then be transversely cut using one or more finishing devices 312 to separate the continuous composite laminate 400 into a series of end-to-end longitudinal segments 401, as shown in fig. 59-62 and described below.

The manufacturing system 100 may include means for aligning and/or directing the lamination surface 120 to the lamination station 150. For example, in addition to the above-described longitudinal rails 140 that may maintain the lateral alignment of one or more lamination mandrels 122 relative to the lamination head 152 in the lamination station 150, the manufacturing system 100 may include a means for indexing the longitudinal position of the lamination mandrels 122 relative to the lamination head 152 each time the lamination mandrels 122 enter and pass through the lamination station 150. Such means for indexing the longitudinal position of lamination mandrel 122 may allow lamination head 152 to independently start and stop dispensing of paving material 228 at predetermined locations on lamination mandrel 122. For embodiments of the manufacturing system 100 having a laminating belt 124 (FIG. 5), a similar device for longitudinally indexing the laminating belt 124 relative to the laminating head 152 can allow the laminating head 152 to independently start and stop dispensing the paving material 228 at predetermined locations on the laminating belt 124. Such means for directing may include an optical system (e.g., a laser device-not shown) mounted at the laminating station 150 and configured to detect and register one or more targets (not shown) that may be included on the laminating surface 120 (e.g., one or more laminating mandrels 122, laminating strips 124) moving through the laminating station 150. As can be appreciated, the manufacturing system 100 can include any one or more of a variety of system configurations for directing the lamination surface 120 to the lamination station 150.

Referring to fig. 5, a side view of an embodiment of the laminating station 150 is shown in which the laminating surface 120 is an outer surface (e.g., an upper surface) of one or more continuous annular laminating belts 124. In the illustrated embodiment, a plurality of laminate strips 124 are arranged in end-to-end relationship with one another and are supported by one or more base members 102. Each laminate strip 124 may be made of a flexible material such as rubber, plastic, a hinged metal mesh, or a series of short rigid plates connected in end-to-end relationship. However, the laminate tape 124 may be provided in any of a variety of other configurations. Each laminate strip 124 may be supported by a series of inner strip rollers 126, the inner strip rollers 126 being arranged in parallel relationship to one another and configured to support the laminate strip 124 in a manner that prevents excessive deflection of at least the outer surface of the laminate strip 124 on which the composite laminate 400 is supported. One or more belt rollers 126 may be rotatably driven by a drive motor (not shown) to move the laminating belt 124.

Regardless of the configuration of the laminating surface 120, the laminating surface 120 may be moved in the first direction of travel 128 from a laminating surface home position 134 (fig. 1-2), through a laminating station 150, and to a laminating surface back position 136. The laminating surface 120 can also travel in a second direction of travel 130 (not shown) from a laminating surface back position 136 (fig. 1-2), through a laminating station 150, and to a laminating surface home position 134. The movement of the lamination surface 120 is generally aligned with the dispensing direction 204 (fig. 6) of the lamination head 152. In fig. 5, the manufacturing system 100 is shown with at least one finishing device 312 positioned at each of the opposite ends of the laminating station 150 to allow finishing of the composite laminate 400 moving with the laminating belt 124 along the first direction of travel 128 shown in fig. 5 and/or finishing of the composite laminate 400 moving along the second direction of travel 130 while reversing the direction of movement of the laminating belt 124.

The manufacturing system 100 may include a lamination surface preparation position 132 (fig. 1-2) and a lamination surface unloading position 138 (e.g., fig. 44, 48, 54) located adjacent to a lamination surface origination position 134. As described in more detail below, the lamination surface preparation position 132 can provide a position for holding the lamination surface 120 (e.g., the second lamination mandrel) while the other lamination surface 120 (e.g., the first lamination mandrel) occupies the lamination surface home position 134. The lamination surface unloading location 138 may provide a location for maintaining a lamination surface 120 (e.g., one or more lamination mandrels) supporting a completed (e.g., laid-up and trimmed) composite laminate 400 while the composite laminate 400 is unloaded to another location for further processing, e.g., compaction, forming and/or curing.

Referring briefly to fig. 3-6 and 14, the lamination head 152 may be supported on the support frame 104. In the illustrated embodiment, each lamination head 152 is supported on a dedicated support frame 104. Each support frame 104 may include a generally horizontally oriented cross beam 108, the cross beam 108 having opposite ends coupled to a pair of generally vertically oriented posts 106, respectively, the posts 106 extending upwardly from the base member 102. Each of the beams 108 may include a linear actuation mechanism (e.g., a screw drive rotatably driven by a servo motor (not shown)) configured to translate the lamination head 152 horizontally along the beam 108 to allow the lamination head 152 to be moved laterally into alignment with the remaining lamination heads 152 to allow servicing of the laterally moved lamination heads 152, as described in more detail below. The struts 106 of each support frame 104 may include a linear actuation mechanism (not shown). The linear actuation mechanisms of the posts 106 of each support frame 104 may operate in a coordinated manner to vertically translate the cross beam 108 as a means for vertically positioning the lamination heads 152 relative to the lamination surface 120, as described below.

In addition, each support frame 104 may include a rotational actuation mechanism (e.g., a servomotor — not shown) to rotate the lamination head 152 about the vertical axis 174 (fig. 14) to rotate the first side 158 (e.g., fig. 6 and 14) of the lamination head 152 out of the material application position 206 (e.g., fig. 6 and 14) into the material reload position 208 (fig. 6) and/or to rotate the second side 160 (e.g., fig. 6 and 14) of the lamination head 152 into the material application position 206. Rotating the first side 158 to the material reload position 208 may allow access to the first side 158 for servicing the head component 220 on the first side 158, such as replacing a depleted roll of material 224 (fig. 16) or performing maintenance on the head component 220. Rotating second side 160 to material application position 206 allows lamination head 152 to dispense paving material 228 before or after servicing first side 158.

Although the lamination head 152 is described as being supported by a plurality of support frames 104, as shown in fig. 1-6, the lamination head 152 may be supported by any of a variety of alternative structural arrangements including, but not limited to, a cantilever beam (not shown), a robotic device (not shown), or any of a variety of other structural arrangements and/or mechanisms for maintaining the lamination heads 152 in end-to-end relationship with each other while the lamination head 152 applies the paving material 228 onto the lamination surface 120 moving under the lamination head 152.

Referring to fig. 3-6, the series of lamination heads 152 may be arranged linearly to form a composite laminate 400 having a linear shape. However, in an embodiment not shown, the manufacturing system 100 may include a series of lamination heads 152 in a non-linear arrangement, such as for forming a composite laminate 400 having a non-linear shape (e.g., an arcuate shape). The lamination surface 120 can be configured to move along a path that is complementary to the arrangement (e.g., linear or non-linear) of the lamination heads 152. In another embodiment, not shown, the lamination heads 152 may be arranged in a two-dimensional array of lamination heads 152 defining a length and a width of the lamination station 150. In this regard, the lamination heads 152 may be arranged in two or more series of lamination heads 152, with the series of lamination heads 152 arranged in side-by-side relationship with one another. For example, the lamination heads 152 may be arranged as a first series of lamination heads (not shown) and a second series of lamination heads (not shown) positioned in side-by-side relationship with the first series of lamination heads.

Referring to fig. 5-6, in any of the embodiments of the manufacturing system 100 disclosed herein, the lamination surface 120 (e.g., lamination mandrel 122, lamination band 124) can include a plurality of apertures 144 (fig. 6) that can be fluidly coupled (e.g., via internal fluid conduits-not shown) to a vacuum pressure source 146 (fig. 5) that can be included within the manufacturing system 100. The vacuum pressure source 146 may generate vacuum pressure via the holes 144 at the outer surface of the lamination surface 120 as a means to immovably secure the composite laminate 400 to the outer surface at least during application of the layup material 228 onto the lamination surface 120 or onto a layup material 228 previously applied to the lamination surface 120. In some embodiments, a treatment layer (not shown), such as a layer of a release sheet (e.g., fluorinated ethylene propylene), may be applied to laminate surface 120 prior to dispensing paving material 228 onto laminate surface 120. This peel ply may prevent contamination of the outermost surface of composite laminate 400 and may thereby maintain the bondability of composite laminate 400 after laying is complete and the peel ply is removed. Vacuum pressure may secure the layer of peel ply to the lamination surface 120. The tackiness of the paving material 228 may adhere to the peel ply layer to an extent that prevents the paving material 228 from shifting (e.g., laterally) relative to the lamination surface 120 during the paving process.

In fig. 1-6, the lamination heads 152 are shown as being evenly spaced from one another. However, in an embodiment not shown, the lamination heads 152 may be non-uniformly spaced apart from one another. Although the lamination heads 152 in fig. 1-6 are shown positioned in close proximity to each other, in alternative embodiments, the lamination heads 152 may be arranged such that there is a gap (e.g., a uniform gap and/or a non-uniform gap) between the lamination heads 152 that allows each lamination head 152 to pivot about the vertical axis 174 without contacting adjacent lamination heads 152 and without moving (e.g., translating horizontally or vertically) the lamination heads 152 out of alignment with the remaining lamination heads 152. As described below, the lamination head 152 may be pivoted about its vertical axis 174 to rotate the first side 158 of the lamination head 152 out of alignment with the lamination head 152 and move the first side 158 to the material reload position 208 for servicing the head component 220 on the first side 158.

Referring briefly again to fig. 1-4, as described above, manufacturing system 100 includes one or more finishing devices 312 for finishing composite laminate 400. For example, one or more finishing devices 312 may be positioned proximate at least one of the opposing ends of the laminating station 150. In the embodiment of fig. 1-2, the manufacturing system 100 includes a finishing station 310 located between the lamination surface origination location 134 and the lamination station 150, and/or a finishing station 310 located between the lamination station 150 and the lamination surface back location 136. In the illustrated embodiment, each finishing station 310 includes four (4) finishing devices 312 for finishing composite laminate 400. However, finishing station 310 may include any number of finishing devices 312, including, for example, a single finishing device 312. In an embodiment, the trimming device 312 may be configured to trim at least one of the opposing side edges 414 of the composite laminate 400 during movement of the lamination surface 120 from the lamination station 150 to the lamination surface aft position 136 (see, e.g., fig. 42) and/or during movement of the lamination surface 120 from the lamination station 150 to the lamination surface home position 134 (see, e.g., fig. 47), as described in more detail below. The trimming device 312 may be configured to trim the side edges of the composite laminate 400 at any location along the length of the composite laminate 400. For example, finishing device 312 may be configured to finish composite laminate 400 to form tab(s) 412 (e.g., fig. 44) at one or both of the opposing ends of composite laminate 400. However, one or more finishing devices 312 in lamination station 150 may be configured to finish portions of composite laminate 400 other than side edges 414. For example, one or more finishing devices 312 may be configured to finish one or both of the opposing ends of composite laminate 400, or to form a geometric feature (e.g., an aperture) in composite laminate 400 anywhere between opposing side edges 414. The finishing device 312 may be controlled by the controller 110 to finish the composite laminate 400 in coordination with the movement (e.g., speed and position) of the lamination surface 120.

Referring to fig. 6-7, each lamination head 152 includes at least one material supply roll 222 supporting a roll of material 224. In the illustrated embodiment, the laminating head 152 is configured to dispense paving material 228 supported by a backing layer 230. Backing layer 230 may be formed of a material that prevents adjacent cladding layers (wrap) of paving material 228 from adhering to each other on roll of material 224. For example, backing layer 230 may be silicone coated paper, or backing layer 230 may be a thin plastic film, such as a polyethylene film. For a laminating head 152 configured to dispense paving material 228 with a backing layer 230, the head component 220 may include a material supply roll 222, a material dispensing mechanism 260, and a backing layer collection roll 300. Laminating heads 152, 142 may additionally include one or more re-direction rollers 234 for directing or guiding paving material 228 (e.g., optionally supported by backing layer 230) through head member 220 and/or for maintaining tension in paving material 228 and/or backing layer 230 during dispensing of paving material 228 from laminating head 152.

The paving material 228 may be provided as a continuous strip of fibre reinforced polymer matrix material, such as a prepreg strip. Paving material 228 may be provided in any of a variety of thicknesses and widths. For example, the layup material 228 may be provided as a prepreg tape having a thickness of 0.007 inches or more and a width of 9 to 12 inches, although the layup material 228 may be provided at a thickness greater than 0.007 inches and/or a width narrower than 9 inches or wider than 12 inches. The lamination station 150 may include one or more lamination heads 152, the lamination heads 152 supporting a roll 224 of material formed from slit strips that may be narrower than the prepreg strips supported on the other lamination heads 152 in the lamination station 150. The fibres in the prepreg tape may be unidirectional or the fibres may be arranged as a woven fabric. The polymeric matrix material of the prepreg tape may be a thermosetting resin or a thermoplastic resin. The fibers may be carbon fibers or the fibers may be formed of alternative materials such as glass, boron, aramid, ceramic or other non-metallic or metallic materials. The prepreg tape may also be provided with carbon fibers and metal fibers or mesh to provide overall lightning strike protection for the composite laminate 400.

In some embodiments, the material supply drum 222 may be configured to support a roll 224 of non-composite material. For example, the roll of material 224 of one or more lamination heads 152 may be formed from a layup material 228, such as a metal foil or mesh, and it may be dispensed by the lamination heads 152 to form one of the plies 402 of the composite laminate 400. In further embodiments, one or more rolls 224 of lamination heads 152 may include a layup material 228 disposed as a treatment layer for composite laminate 400. Such treatment layers may include a release film, a tackifier film, a breathable layer, a release layer, a peel ply layer, or any of a variety of other layers, films, or adhesives, which may be laid prior to or during laying up of composite laminate 400 to facilitate laying up, compacting, shaping, and/or curing of composite laminate 400 during or after laying up and finishing of composite laminate 400. In one embodiment, the roll of material 224 of one or more lamination heads 152 may be formed from a material designed to enhance impact toughness or reduce moisture intrusion or improve other properties of the composite laminate. For laminating heads 152 loaded with paving material 228 that may not have a backing layer 230 (e.g., thermoplastic, metal foil, a treatment layer such as a non-adhesive film), the above-described backing layer collection drum 300 and associated backing layer separation hardware (e.g., backing layer separation device 264) can be omitted from such laminating heads 152, or such backing layer collection drum 300 and associated backing layer separation hardware can be unused or inactive during the dispensing of such material.

Still referring to fig. 6-7, for example, where the roll 224 includes a backing material 226 comprised of a paving material 228 (the paving material 228 being supported by a backing layer 230), the material dispensing mechanism 260 is configured to receive the backing material 226 from the material supply roll 222, separate the paving material 228 from the backing layer 230, and dispense the paving material 228 onto the laminating surface 120 along the dispensing direction 204. Material dispensing mechanism 260 may include backing layer separation device 264 for separating paving material 228 from backing layer 230, cutter assembly 240 for cutting paving material 228 while leaving backing layer 230 intact, and one or more compression devices 288, such as compression rollers and/or compression shoes, for compressing paving material 228 onto laminating surface 120 or onto previously applied paving material 228 as paving material 228 is dispensed from laminating head 152.

The backing layer collection roller 300 is configured to take up the backing layer 230 after the backing layer 230 is separated from the paving material 228. In the embodiment of fig. 6-7, each lamination head 152 is configured to dispense a paving material 228 onto a lamination surface 120 moving in a single direction of travel (e.g., in a first direction of travel 128 or in a second direction of travel 130 opposite the first direction of travel 128). However, as described below, one or more of the laminating heads 152 may have a bi-directional layup capability, wherein the laminating head 152 is capable of dispensing a layup material 228 onto the laminating surface 120 moving both along the first direction of travel 128 and along the second direction of travel 130.

In the present disclosure, operation of the manufacturing system 100, including movement of the lamination surface 120, operation of the head assembly 220 of each lamination head 152, and movement (e.g., lateral translation, vertical translation, and/or rotation about the vertical axis 174) of each lamination head 152 within the lamination station 150, may be controlled by the controller 110 (fig. 1) executing calculable readable program instructions (e.g., a numerical control program) that may be preprogrammed for manufacturing the composite laminate 400.

Each lamination head 152 may include a cutter assembly 240 controlled by the controller 110 and configured to cut the paving material 228 as the lamination head 152 approaches each designated start position (not shown) of a ply 402 of paving material 228 applied by the lamination head 152 and as the lamination head 152 approaches each designated end position (not shown) of the ply 402. Controller 110 may control lamination head 152 and corresponding cutter assembly 240 in a manner that begins application of paving material 228 at the same starting location on lamination surface 120 or at a different starting location on lamination surface 120. Alternatively or additionally, controller 110 may control lamination heads 152 and respective cutter assemblies 240 in a manner that application of paving material 228 is stopped at the same stop location on lamination surface 120 or at a different stop location on lamination surface 120 as described below. As also described below, the controller 110 may also control the lamination heads 152 to independently start, stop, and/or restart the application of paving material 228 from any one or more of the lamination heads 152 at any location along the lamination surface 120 to form build-up, subtractive, and/or partial plies within the composite laminate 400.

Referring to fig. 8-10, a table of an embodiment of a material configuration 406 of paving material 228 dispensed by each of the ten (10) laminating heads 152 (fig. 10) in the laminating station 150 (fig. 10) is shown in fig. 8. Each lamination head 152 is loaded with a roll 224 of paving material 228, which roll 224 has a material configuration 406 corresponding to the desired ply stacking sequence 410 of composite laminate 400. As described above, the ply stacking sequence 410 of the composite laminate 400 is defined by the position of the lamination heads 152 relative to each other within the lamination station 150. The order of stacking of the plies of composite laminate 400 may be based on the end use of composite laminate 400. More specifically, composite laminate 400 may be designed to have a certain ply stacking order based on a set of predetermined design loads to which the final composite laminate 400 may be subjected (e.g., after curing) in use. In this regard, the order of the lamination heads 152 may be dictated by the end use of the composite laminate 400.

For example, in fig. 8, the laminating head 152, designated head No. 1, is loaded with a layup material 228 having a material configuration 406 composed of 0/90 degree woven prepreg strips. Head number 2 is loaded with paving material 228 having a material configuration 406 composed of 0 degree unidirectional strips. Head No. 3 is loaded with a layup material 228 having a material configuration 406 composed of 0 degree Unidirectional (UD) prepreg tape. Fig. 9 is a cross-sectional view of a composite laminate 400 having a ply stacking sequence 410, the ply stacking sequence 410 resulting from the sequential application of paving material 228 dispensed by all ten (10) lamination heads 152 listed in fig. 8 during a single pass of lamination surface 120 through lamination station 150. In fig. 9, sheet 1 of composite laminate 400 of fig. 9 is applied by head No. 1, sheet 2 of composite laminate 400 is applied by head No. 2, sheet 3 of composite laminate 400 is applied by head No. 3, and so on.

In fig. 9, composite laminate 400 has a total of ten (10) plies 402 as a result of a single pass through lamination surface 120 of lamination station 150 (e.g., along first direction of travel 128 or along second direction of travel 130). However, composite laminate 400 may be formed by multiple passes of lamination surface 120 through lamination station 150. In an embodiment not shown, composite laminate 400 having a total of 20 plies 402 may be produced by ten (10) lamination heads 152 applying ten (10) plies 402 of paving material 228, respectively, as lamination surface 120 moves in first direction of travel 128 from lamination surface origin position 134 to lamination surface back position 136, and ten (10) lamination heads 152 applying another ten (10) plies 402 of paving material 228 in reverse order from the first ten (10) plies 402 as lamination surface 120 moves in second direction of travel 130 from lamination surface back position 136 to lamination surface origin position 134.

In fig. 9, the paving material 228 dispensed by each of the ten (10) laminating heads 152 has the same material width 408. However, as described below, the paving material 228 dispensed by one or more laminating heads 152 can have different material widths 408. In some embodiments, the material width 408 of the paving material 228 loaded onto each lamination head 152 may be selected such that one or both of the opposing lateral side edges 414 of the composite laminate 400 are formed at a bevel 416 (e.g., fig. 12-13) that is not oriented perpendicular to the surface of the composite laminate 400. Selecting the width 408 of the material that creates the bevel 416 may advantageously avoid the need to trim the side edges 414 at the bevel 416.

In the present disclosure, the manufacturing system 100 (fig. 1-2) may be configured such that the lamination head 152 (fig. 1-2) is controlled by the controller 110 (fig. 1) in such a way that application of the paving material 228 (fig. 1-2) is started at the same start position on the lamination surface 120 (fig. 1-2) and/or stopped at the same stop position on the lamination surface 120, and when completed, a constant laminate thickness is produced along the entire length of the composite laminate 400 (fig. 1-2). Alternatively, lamination head 152 may be controlled by controller 110 to start applying paving material 228 at different locations on lamination surface 120 and/or stop applying paving material 228 at different locations on lamination surface 120, and when completed, produce a laminate thickness that varies along the longitudinal direction of composite laminate 400. Additionally, any of the lamination heads 152 in lamination station 150 may be controlled by controller 110 to start, stop, and/or restart application of paving material 228 at any point along lamination surface 120 during paving of composite laminate 400.

Any one or more of the lamination heads 152 can be controlled by the controller 110 to stop applying the paving material 228 at any location along the lamination surface 120 while the remaining lamination heads 152 within the lamination station 150 continue to apply the paving material 228. In some embodiments, lamination head 152, which has been commanded to stop applying paving material 228 at one point along lamination surface 120, may be restarted to resume applying paving material 228 at another point along lamination surface 120 and create a longitudinal gap 404 (fig. 11) or a subtractive (ply drop) in one of plies 402 of composite laminate 400 as described below. As can be appreciated, during laying up of composite laminate 400, the multiple lamination heads 152 within lamination station 150 may be stopped and restarted at one or more points and one or more gaps 404 created within the multiple plies 402 of composite laminate 400.

Referring to fig. 10-11, a schematic view of a series of laminating heads 152 applying a layup material 228 to a laminating surface 120 is shown. Fig. 10 shows a series of ten (10) laminating heads 152, with heads No. 1 through 5 applying a layup material 228 to the laminating surface 120 at a first point in time during movement of the laminating surface 120 through the laminating station 150 in the first direction of travel 128. Fig. 11 shows the series of ten (10) laminating heads 152 at a second point in time during which heads No. 1-7 apply a layup material 228 to the laminating surface 120 during movement in the first direction of travel 128. As shown in fig. 11, composite laminate 400 includes a gap 404 in ply 2 due to the stop and restart of the application of paving material 228 by the No. 2 head. On each side of gap 404, portions of ply 2 remain between ply 1 and ply 3, and ply 1 and sheet 3 are continuous at least in fig. 11. Manufacturing system 100 may be configured such that any one or more of lamination heads 152 may independently start, stop, and/or restart application of paving material 228 at one or more points in time as lamination surface 120 moves through lamination station 150. Further, the lamination heads 152 may be operated in a manner such that less than the total number of lamination heads 152 within the lamination station 150 begin to apply the layup material 228 at the same location on the lamination surface 120. For example, for a lamination station 150 having a total of ten (10) lamination heads 152 including heads No. 1-10, only heads No. 2-10 may initially dispense paving material 228 onto the moving lamination surface 120, after which head No. 1 may be activated to begin dispensing paving material 228 at a different point in time while heads No. 2-10 continue to apply paving material 228.

Referring to fig. 12-13, a transverse cross-sectional view of an embodiment of composite laminate 400 composed of paving material 228 having different material widths 408 is shown. In some embodiments, the different material widths 408 may be obtained by pre-cutting a prepreg strip that is then wound into a roll of material 224 (fig. 10-11) for loading onto the lamination head 152 (fig. 10-11). Fig. 12 is a cross-sectional view of an embodiment of composite laminate 400 in which paving material 228 dispensed by each of the ten (10) lamination heads 152 (e.g., heads No. 1-10 in fig. 8) has a different material width 408, and this results in each of the opposing side edges 414 of composite laminate 400 being formed at an oblique angle 416. The material width 408 of the paving material 228 on the roll of material 224 on each lamination head 152 may be selected such that both opposing side edges 414 of the composite laminate 400 are formed at a predetermined bevel 416.

In fig. 12, the material width 408 is such that the bevel 416 on each side edge 414 is about 20 degrees. It is understood, however, that material width 408 of paving material 228 may be selected to produce any of a variety of different bevels 416. Fig. 13 is a cross-sectional view of a composite laminate 400 (e.g., composite laminate 400 of fig. 12) manufactured by dispensing paving material 228 from less than the total number of lamination heads 152 used in the same lamination station 150 used to manufacture composite laminate 400 of fig. 12. In fig. 13, a cross section of composite laminate 400 includes paving material 228 dispensed from heads No. 1,3, 5, 7, and 10, and results in a cross section consisting of

plies

1, 2, 3, 4, and 5. The output of header No. 1 is that of slice 1, header No. 3 is that of slice 2, header No. 5 is that of slice 3, header No. 7 is that of slice 4, and header No. 10 is that of slice 5. The reduced number of plies in fig. 13 results in a smaller bevel angle 416 (e.g., about 9 degrees) relative to the bevel angle 416 of the cross-section in fig. 12.

Still referring to fig. 12-13, the paving material 228 for each cross-section may be applied such that centerlines (not shown) of plies 402 are laterally aligned or coincident with each other and result in a lateral cross-section of composite laminate 400 that is symmetric about a laminate vertical axis (not shown). However, in an embodiment not shown, lamination head 152 may apply layup material 228 such that the centerline of at least one ply 402 is laterally offset from the centerlines of the other plies 402 and results in a transverse cross-section of composite laminate 400 that is asymmetric about the laminate vertical axis.

Referring to fig. 14, an embodiment of a lamination head 152 supported on the lamination mandrel 122 by the support frame 104 is shown. In the illustrated embodiment, the lamination head 152 includes laterally opposite sides including a first side 158 and a second side 160, each of the first side 158 and the second side 160 having the head member 220 described above. For example, the lamination head 152 includes a first lamination assembly 200 mounted to the first side 158. The first lamination assembly 200 includes the material supply roll 222, the backing layer collection roll 300, and the backing layer separator assembly 262 as described above. The laminating head 152 also includes a second laminating assembly 202 mounted to the second side 160, which second laminating assembly 202 can have the same arrangement of material supply roll 222, backing layer collection roll 300, and backing layer separation assembly 262 as in the first laminating assembly 200. However, in an embodiment not shown, the head component 220 of the second lamination assembly 202 may be arranged differently from the head component 220 of the first lamination assembly 200 or may have a different configuration.

In the present disclosure, the lamination heads 152 may be configured such that the first side 158 is movable to a material application position 206 that is aligned with the dispensing direction 204 (fig. 7) of the other lamination heads 152 in the lamination station 150. When the first side 158 of the lamination head 152 is in the material application position 206, the first lamination assembly 200 may apply a layup material 228 (fig. 7) onto the lamination surface 120 or onto a previously applied layup material 228. When the first side 158 is in the material application position 206, the second side 160 may be in the material reload position 208, which may allow for servicing of the second side 160 of the laminating head 152. As described above, servicing the lamination head 152 may include replacing the roll of material 224, performing maintenance or other activities on the head assembly 220. Instead of moving the first side 158 to the material application location 206, the second side 160 of the lamination head 152 may be moved to the material application location 206 such that the second side 160 is aligned with the remaining lamination heads 152 in the lamination station 150 and allows the second lamination assembly 202 to apply a layup material 228 to the lamination surface 120 or to a previously applied layup material 228. When the second side 160 is in the material application position 206, the first side 158 may be in the material reload position 208, which may allow for servicing of the first side 158.

Still referring to fig. 14, one or more lamination heads 152 within the lamination station 150 may be configured to independently rotate 180 degrees about a vertical axis 174. Prior to rotating the lamination head 152 about the vertical axis 174, the lamination head 152 may be translated until the lamination head 152 is moved out of alignment with the remaining lamination heads 152 that may remain positioned above the lamination surface 120. In the embodiment of fig. 14, the lamination heads 152 are shown as being translated horizontally along the beam 108 out of alignment with the remaining lamination heads 152 by means of a linear actuation mechanism (not shown) that may be included within the beam 108. Moving the lamination heads 152 out of alignment with the remaining lamination heads 152 may provide clearance for rotating the lamination heads 152 without contacting the remaining lamination heads 152. Rotating the lamination head 152 an amount of 180 degrees about the vertical axis 174 may result in positioning the first side 158 or the second side 160 at the material application location 206, and may also result in positioning the remaining one of the first side 158 or the second side 160 at the material reload location 208. In the present disclosure, when one side of the lamination head 152 (i.e., the first side 158 or the second side 160) is in the material reload position 208, the side faces away from the lamination surface 120 (e.g., the lamination mandrel) and/or the side is not aligned with the lamination surface 120.

Referring to fig. 15, an embodiment of a mechanism for supporting one or more finishing assemblies 312 is shown. The mechanism includes a support frame 104 configured similar to the support frame 104 described above for supporting the lamination head 152. For example, the support frame 104 for the one or more finishing devices 312 may be a generally horizontally oriented beam 108 coupled at each end to a pair of generally vertically oriented posts 106 extending upwardly from the base member 102. During trimming of composite laminate 400 or during other operations of the manufacturing system, trimming device 312 may be laterally translated along beam 108 by a linear actuation mechanism (not shown). The lateral translation of the trimming device 312 may facilitate cutting or trimming any of a variety of geometries in the composite laminate 400, such as the protrusions 412 described above (e.g., fig. 44).

In another embodiment, the vertical height of the trimming device 312 may be adjusted by vertically translating the cross beam 108 via a linear actuation mechanism (not shown) that may be included in each post 106. Adjusting the vertical height of the trimming device 312 may accommodate trimming of different laminate thicknesses, such as trimming a composite laminate 400 having a laminate thickness that varies along the length of the composite laminate 400. In some embodiments, one or more finishing devices 312 may be coupled to cross-beam 108 or other structure by a multi-axis connecting element (e.g., a five-axis pivot element — not shown) to allow for pivoting of finishing devices 312 to change the orientation of finishing devices 312 while finishing composite laminate 400. As an alternative to the support frame 104 shown in fig. 15, one or more finishing devices 312 may be supported by a cantilever beam mechanism (not shown), a robotic device (not shown), or any of a variety of other structures or mechanisms.

In fig. 15, one or more of the trimming devices 312 may be configured as an ultrasonic blade, a laser device, a mechanical cutter blade, or any of a variety of other types of trimming devices 312. As described above, the trimming device 312 may be configured to trim one or both of the side edges 414 of the composite laminate 400. Alternatively or additionally, the one or more trimming devices 312 may trim or cut other locations of the composite laminate 400, such as the ends of the composite laminate 400 for the interior regions of the composite laminate 400. In the embodiments illustrated in fig. 42, 47, 52, and 57 described below, one or more finishing devices 312 may finish composite laminate 400 while composite laminate 400 is being laminated. For example, as lamination mandrel 122 passes through lamination station 150, a downstream portion of composite laminate 400 exiting lamination station 150 may be trimmed while an upstream portion of composite laminate 400 is being laid up. Trimming composite laminate 400 may include one or more trimming devices 312 forming a vertical cut on composite laminate 400, for example, on one or both side edges 414. The vertical cuts may be oriented perpendicular to the uppermost lamination surface 120. Alternatively or additionally, one or more finishing devices 312 may form oblique cuts on one or both side edges 414 of composite laminate 400. The oblique cuts may not be oriented perpendicular to the uppermost laminate surface 120 and may be formed on one or both side edges 414 of the composite laminate 400.

Referring to fig. 16-19, a top view of a portion of the lamination stations 150 is shown illustrating the process of laterally translating one of the lamination heads 152 out of alignment with the remaining lamination heads 152 in the lamination station 150 prior to rotating the translated lamination head 152 an amount of 180 degrees about the vertical axis 174 (fig. 14). As described above and shown in fig. 14, one or more lamination heads 152 of lamination station 150 may have a first side 158 and a second side 160, each of the first side 158 and the second side 160 configured to dispense a paving material 228 (fig. 7). Fig. 16 shows one of the lamination heads 152 laterally translated out of alignment with the series of lamination heads 152 to allow replacement of the depleted roll of material 224 on the first side 158 of the lamination head 152. Fig. 17 shows the lamination head 152 rotated 180 degrees about the vertical axis 174 such that the second side 160 of the lamination head 152 is rotated to the position previously occupied by the first side 158 of the lamination head 152.

As described above, the lamination heads 152 may be laterally translated out of alignment with the remaining lamination heads 152 to provide clearance for the rotating lamination heads 152. Fig. 18 shows the lamination head 152 laterally translated back into alignment with the series of lamination heads 152, which places the second side 160 at the material application location 206. Fig. 19 shows a roll of replacement material 224 mounted on a first side 158 of the laminating head 152, the first side 158 being in the material reload position 208. The replacement roll of material 224 may be installed after the depleted roll of material 224 is removed from the first side 158. An advantage of rapidly translating lamination head 152 out of alignment with the remaining lamination heads 152 to rotate lamination head 152 and then rapidly moving second side 160 of lamination head 152 to a position for dispensing paving material 228 is to minimize downtime to lay up composite laminate 400, thereby maximizing throughput of manufacturing system 100.

Referring to fig. 20-21, an end view of an embodiment of the manufacturing system 100 configured to allow vertical translation of one or more lamination heads 152 out of alignment with the series of lamination heads 152 is shown. Similar to the arrangement described above with respect to fig. 14, laminating head 152 shown in fig. 20 has a first side 158 and a second side 160, each of first side 158 and second side 160 configured to dispense paving material 228. The lamination head 152 is supported by a beam 108, which beam 108 is vertically translatable, for example, by coordinated actuation of a pair of linear actuation mechanisms (not shown), which may each be included in a post 106 extending upwardly from the base member 102. Fig. 21 shows the lamination heads 152 after independently translating upward out of alignment with the remaining lamination heads 152 to provide clearance for rotating the lamination heads 152 without contacting the remaining lamination heads 152 in the lamination station 150. In fig. 21, the lamination head 152 may be rotated 180 degrees about the vertical axis 174 (fig. 14) such that the second side 160 of the lamination head 152 is rotated to the position previously occupied by the first side 158 of the lamination head 152, after which the lamination head 152 may be translated back down into alignment with the remaining lamination heads 152. With the first side 158 of the laminating head 152 in the material reload position 208 (fig. 20), the depleted roll of material 224 on the first side 158 of the laminating head 152 may be replaced with a roll of replacement material 224. As described above, the ability to rapidly translate the lamination head 152 upward out of alignment with the remaining lamination heads 152, and then rotate the lamination head 152 and translate the second side 160 of the lamination head 152 downward to the material application location 206 (fig. 20) to dispense the layup material 228 minimizes the downtime of the manufacturing system 100 to lay up the composite laminate 400.

Referring to fig. 22-25, a top view of an embodiment of manufacturing system 100 is shown in fig. 22, wherein the series of lamination heads 152 are mounted on a horizontal shaft 176. Fig. 23 is a side view of the manufacturing system 100 of fig. 22. Fig. 24 is a cross-sectional view of manufacturing system 100 showing one of lamination heads 152 supported on horizontal shaft 176. Fig. 25 is a cross-sectional view showing one of a pair of opposing shaft supports 178, the shaft supports 178 being configured to support a horizontal shaft 176 that may extend between the opposing shaft supports 178. Each shaft support 178 may include a linear actuation mechanism that may operate in cooperation with one another to vertically translate horizontal shaft 176 and thereby vertically translate lamination heads 152 before and after one or more lamination heads 152 rotate over horizontal shaft 176.

As shown in fig. 24, the mounting frame 154 of each lamination head 152 can be rotatably coupled to a horizontal shaft 176. As described above, one or more lamination heads 152 in lamination station 150 may have a first side 158 and a second side 160, each of the first side 158 and the second side 160 configured to dispense a paving material 228 (fig. 7). In the embodiment of fig. 22-28, the arrangement of the header components 220 on the second side 160 of each lamination head 152 may be reversed relative to the arrangement of the header components 220 on the first side 158 of the lamination head 152. Each lamination head 152 may be independently rotatable at least 180 degrees about horizontal axis 176 in such a manner that second side 160 of lamination head 152 is rotated to the position previously occupied by first side 158 of lamination head 152 to allow second side 160 to dispense paving material 228. Rotation of the laminating head 152 over the horizontal axis 176 may also move the first side 158 to the material reload position 208 to allow a depleted roll of material 224 on the first side 158 to be replaced with a replacement roll of material 224 and/or to allow maintenance of the first side 158. As described above, in embodiments where the lamination heads 152 are independently rotatable 180 degrees about the vertical axis 174 (e.g., fig. 16-19), the ability to rotate one or more lamination heads 152 about the horizontal axis 176 allows for quickly rotating the depleted side of the lamination head 152 out of alignment with the remaining lamination heads 152 in the lamination station 150 and quickly rotating the side of the lamination head 152 with the full roll of material 224 to the material application location 206, thereby minimizing downtime to lay up the composite laminate 400, which thereby maximizes throughput of the manufacturing system 100.

Referring to fig. 26-28, an end view of the laminating station 150 of fig. 22-23 is shown illustrating the process of rotating the laminating head 152 about horizontal axis 176. The first side 158 of the laminating head 152 contains a depleted roll of material 224. Fig. 26 shows horizontal axis 176 and the series of lamination heads 152 translated upward to provide clearance for lamination mandrel 122 during rotation about horizontal axis 176. Fig. 27 illustrates rotation of one of the lamination heads 152 to rotate the second side 160 of the lamination head 152 to the position previously occupied by the first side 158 of the lamination head 152. Fig. 28 shows horizontal axis 176 and the series of laminating heads 152 translated downward to allow second side 160 of laminating head 152 to dispense paving material 228 with one or more of the remaining laminating heads 152 in laminating station 150.

Referring to fig. 29, an embodiment of a lamination head 152 having a mounting frame 154 is shown, the mounting frame 154 having a first side 158 and a second side 160. Lamination head 152 also includes a head module 170 removably coupled to first side 158 and a head module 170 removably coupled to second side 160. Each head module 170 includes a frame coupling element 172, and the head part 220 is mounted to the frame coupling element 172. Each frame coupling element 172 allows each head module 170 to be removably coupled to the mounting frame 154, which may allow the head module 170 to be removed, for example, for servicing the head piece 220, replacing a roll of material 224, or replacing the head module 170, as described below (e.g., fig. 30-33). In the embodiment of fig. 29, frame coupling element 172 is configured as a plate to which head component 220 is mounted. However, frame coupling elements 172 may be provided in any of a variety of alternative structural configurations that can serve as a structure to which head component 220 is mounted. Although not shown, the frame coupling element 172 of each head module 170 may be removably attached to the mounting frame 154 using one or more fastening mechanisms (not shown) incorporated into the mounting frame 154 and/or into the frame coupling element 172, and which may be actuated upon command of the controller 110. In this regard, the fastening mechanism that removably couples the frame coupling element 172 to the mounting frame 154 may be actuated by any of a variety of means including electro-mechanical, pneumatic, and/or hydraulic.

In fig. 29, each head module 170 may be configured to be vertically movable relative to the mounting frame 154. For example, each frame coupling element 172 can include one or more vertical members 180, the vertical members 180 configured to be vertically slidable within a corresponding number of vertical grooves 182, which vertical grooves 182 can be included in the mounting frame 154. However, the frame coupling element 172 of each head module 170 may be configured to have any of a variety of arrangements that enable each head module 170 to move vertically relative to the mounting frame 154. In some embodiments, head modules 170 on one side of mounting frame 154 may be locked in upper position 184 to allow for servicing of head modules 170, while head modules 170 on the opposite side of mounting frame 154 may be moved vertically to allow for distribution of paving material 228. In the embodiment of fig. 29, the head module 170 on the second side 160 is in the material reload position 208 and is shown locked in the upper position 184 while the head module 170 on the first side 158 is in the material application position 206 and is vertically movable in correspondence with starting and stopping dispensing paving material 228. However, the head module 170 on the first side 158 may be locked in the upper position 184 while the head module 170 on the second side 160 may be moved vertically for dispensing paving material 228.

In some embodiments, when head module 170 is in material reload position 208 and locked to upper position 184, such head module 170 may be deactivated such that head component 220 is prevented from moving (e.g., rotating) and/or head module 170 is prevented from moving and/or paving material 228 is dispensed to allow, for example, head module 170 to be serviced or replaced by a technician. As described above, the lamination head 152 may be rotated 180 degrees about the vertical axis 174 to allow the head modules 170 of the first side 158 or the second side 160 to be positioned at the material application location 206 while the head modules 170 of the remaining first side 158 or the second side 160 are positioned at the material reload location 208. In some embodiments, each lamination head 152 may include a rotatable electrical contact mechanism (not shown) configured to automatically electrically disconnect (e.g., cut off power and/or control signals to) the head component 220 of the head module 170 rotated to the material reload position 208 and automatically electrically connect (e.g., provide power and/or control signals to) the head module 170 rotated on one side of the material application position 206. A technical effect of rotating the lamination head 152 to selectively position the first side 158 or the second side 160 at the material reload location 208 or the material application location 206 is the ability to service (e.g., replace the roll of material 224, repair and/or replace the head components 220, replace the head module 170, etc.) the lamination head 152 within the lamination station 150 without disrupting the lay-up of the composite laminate. In this regard, the ability to selectively rotate the first side 158 and the second side 160 of the lamination head 152 between the material application position 206 and the material reload position 208 minimizes downtime of the manufacturing system 100, thereby maximizing throughput of the manufacturing system.

Referring to fig. 30-33, a top view of a portion of the lamination station 150 is shown, wherein each lamination head 152 has a head module 170 mounted to a mounting frame 154, the mounting frame 154 being similar to the arrangement described above with respect to fig. 29. Fig. 30-33 illustrate the process of one of the lamination heads 152 translating laterally out of alignment with the remaining lamination heads 152 in the lamination station 150 to allow replacement of the head module 170 of the laterally translated lamination head 152. However, in an embodiment not shown, the lamination station 150 may be provided in an arrangement in which the series of lamination heads 152 are spaced far enough apart from each other that each lamination head 152 has clearance for rotation 180 degrees about the vertical axis 174 without the need to translate the lamination head 152 out of alignment with the remaining lamination heads 152 in the lamination station 150.

Still referring to fig. 30-33, the head module 170 may be replaced for a number of reasons, including replacing the head module 170 in the event of a depleted roll of material 224 and/or replacing the head module 170 if maintenance of the head component 220 is required or if a differently configured head component 220 is required. Fig. 30 shows the lamination heads 152 laterally translated out of alignment from the series of lamination heads 152. Fig. 31 shows the lamination heads 152 rotated 180 degrees about the vertical axis 174 (fig. 14) such that the head module 170 faces away from the series of lamination heads 152. Fig. 32 shows the head module 170 with a depleted roll 224 being replaced with a head module 170 with a new roll 224. Fig. 33 shows the lamination heads 152 translated back into alignment with the series of lamination heads 152. Replacement of the head module 170 may be performed manually, or replacement of the head module 170 may be performed autonomously by a recharging system 450 configured similar to the recharging system 450 described below and shown in fig. 34-39.

As described above with respect to the embodiments of fig. 16-19 and 20-21, the ability to rapidly rotate the lamination heads 152 and replacement head modules 170 after depleting the roll of material 224 in fig. 30-33 minimizes the amount of downtime of the manufacturing system 100, thereby maximizing throughput. Moreover, the above-described arrangement of frame coupling elements 172 (fig. 29) that removably couple the head modules 170 to the first side 158 and/or the second side 160 of the mounting frame 154 of the lamination head 152 provides the ability to quickly install different types of head modules 170 on any of the lamination heads 152 with minimal downtime of the manufacturing system 100 and with minimal hardware costs. For example, a head module 170 having a head component 220 configured for dispensing a backing material 226 may be quickly replaced with a head module 170 having a head component 220 configured for dispensing a non-backing layup material 228 such as a metal mesh or a non-stick finish (e.g., fig. 30-33). In this regard, any of the embodiments disclosed herein in which the lamination head 152 is rotated (e.g., fig. 16-19, 20-21, 22-28, 29-33) or replaced (fig. 34-39) provides maximum flexibility with respect to material replenishment, material replacement, and/or lamination head maintenance while minimizing overall hardware costs.

In some embodiments of the manufacturing system 100 (e.g., fig. 40), one or more replacement head modules 170 may be stored in close proximity to the laminating station 150 to allow for quick change out of the head modules 170, for example, in the event of a depleted roll of material. In some embodiments, replacement head module 170 may be stored as a replacement for lamination head 152 used to dispense paving material 228 (which paving material 228 has a relatively high demand based on the ply stacking order of the laid composite laminate 400). In contrast, replacement head module 170 may not be stored as a replacement for lamination head 152 used to dispense paving material 228 (which paving material 228 has relatively low demand based on ply stacking order). However, in some embodiments, it may be desirable for the manufacturing system 100 to store a replacement head module 170 that dispenses low demand paving material 228, the replacement head module 170 being predicted to be nearly exhausted at approximately the same time as the lamination head 152 that dispenses high demand paving material 228. In this regard, the head module 170 dispensing the low demand paving material 228 that is nearly depleted may be replaced at the same time as the head module 170 dispensing the high demand paving material 228, which means that the number of times the manufacturing system 100 is paused for head module 170 replacement may be minimized, which may advantageously minimize manufacturing system downtime. In addition, such an arrangement may minimize hardware costs that would otherwise result if manufacturing system 100 were configured to store replacement head modules 170 for each lamination head 152 based on the ply stacking sequence of the composite laminate, regardless of the need for paving material.

Referring to fig. 34-35, an embodiment of a reloading system 450 that may be included in manufacturing system 100 to perform automated (e.g., without human intervention) replacement of lamination heads 152 is illustrated. In one embodiment, the reload system 450 may be actuated by the controller 110 to replace the lamination head 152 when the roll 224 of lamination head 152 is depleted and/or when the lamination head 152 requires maintenance. Fig. 34 is a side view of the manufacturing system 100, showing a reloading system 450 that may extend at least along the length of the laminating station 150. Fig. 35 is a top view of the manufacturing system 100 of fig. 34. In the illustrated embodiment, each lamination head 152 is configured such that a single side (e.g., the first side 158) of the lamination head 152 includes a head feature 220 for applying a layup material 228 (fig. 7) to the lamination surface 120, and an opposite side (e.g., the second side 160) of the lamination head 152 may be free of the head feature 220. The reloading system 450 may include a head transfer mechanism 452, the head transfer mechanism 452 being shown as a generally vertically oriented structural element (e.g., a vertically oriented plate) that is movable via a linear transfer mechanism (not shown) along one or more horizontal rails 457 that extend in the longitudinal direction of the laminating station 150. For example, horizontal rail 457 may extend between a reload station 460 and a holding station 462 of reload system 450. The reload station 460 may be configured to support a replacement lamination head 466. The holding station 462 may be configured to support the removed lamination head 468.

In the embodiment of fig. 34-37, the reload system 450 includes a pair of vertically spaced horizontal rails 457 extending between a reload station 460 and a holding station 462. The head transport mechanism 452 is configured to move along the horizontal rail 457 and remove one of the lamination heads 152 from the lamination station 150, transport the removed lamination head 468 to the holding station 462 (fig. 34), retrieve a replacement lamination head 466 from the reloading station 460 (fig. 34), install the replacement lamination head 466 in the lamination station 150 in place of the removed lamination head 468, and transport the removed lamination head 468 from the holding station 462 to the reloading station 460 for maintenance. As described above, servicing the removed lamination head 468 may include replacing a depleted roll of material 224 on the removed lamination head 468, and may additionally include performing maintenance on the removed lamination head 468. Advantageously, the automated replacement of the lamination heads 152 may be performed relatively quickly, which may reduce down time of the manufacturing system 100 and may thereby increase the rate at which the composite laminate 400 is manufactured.

Fig. 36 shows an embodiment of a header holder 463 at the reload station 460 for supporting a replacement lamination header 466. The manufacturing system 100 may also include a head holder 463 at the holding station 462 for supporting the removed lamination head 468. In the embodiment of fig. 36, the head retainer 463 includes a cantilevered beam that extends laterally outward from the reload system 450. Each head retainer 463 may include a recharger coupling element 464, the recharger coupling element 464 being configured to detachably couple to a head coupling element 156 (fig. 37) that may be included in each lamination head 152. Each recharger coupling element 464 can be removably coupled to head coupling element 156 using any of a variety of means, including magnetic and/or mechanical couplings. The recharger coupling elements 464 of the head holder 463 can be actuated to attach to and detach from the head coupling elements 156 of the lamination head 152 according to instructions of the controller 110.

In fig. 37-39, the head transfer mechanism 452 can include head-engaging beams 454, which head-engaging beams 454 can extend laterally outward from the head transfer mechanism 452 (e.g., fig. 37). The head engagement beam 454 may be vertically movable on the head transfer mechanism 452 by means of a linear actuation mechanism (not shown). For example, as shown in fig. 34, the head transfer mechanism 452 may include one or more vertical rails 458 (fig. 34), along which vertical rails 458 the head engagement beam 454 may translate vertically. Each lamination head 152 may be removably supported on a head support beam 456. The head support beam 456 may extend in a longitudinal direction of the lamination station 150 and may be configured to support a series of lamination heads 152 aligned with one another on the lamination surface 120. In the illustrated embodiment, the head support beam 456 comprises an assembly in which each lamination head 152 is independently removable from the head support beam 456 when the head transfer mechanism 452 engages the head coupling element 156 of one of the lamination heads 152 and translates the lamination head 152 upward as described below.

Still referring to fig. 37-39, the head engagement beam 454 of the head transfer mechanism 452 may include a reload engagement element 470 (fig. 38-39) which reload engagement element 470 may extend laterally from the head engagement beam 454 via a linear actuation mechanism (not shown). As shown in fig. 38, the free end of the recharger engagement element 470 can be configured to engage the head coupling element 156 of one lamination head 152 within the series of lamination heads 152. Once the head coupling element 156 of one of the lamination heads 152 is engaged to the recharger engagement element 470, the head engagement beam 454 may be translated vertically upward (fig. 39) to lift the removed lamination head 468 (fig. 34-35) to the level of the recharger coupling element 464 (fig. 34-35) of the head holder 463 at the holding station 462 (fig. 34-35).

As shown in fig. 34 and described above, the head transfer mechanism 452 is configured to transport the removed lamination head 468 to the holding station 462 (fig. 34-35), whereupon the recharger coupling element 464 of the head holder 463 can be actuated by the controller 110 to couple with the head coupling element 156 of the removed lamination head 468 to transfer the removed lamination head 468 from the head transfer mechanism 452 to the head holder 463. The empty head transport mechanism 452 may then be translated from the holding station 462 to the reloading station 460 whereupon the reloader coupling element 464 of the head holder 463 may be actuated by the controller 110 to release the replacement lamination head 466 to the head transport mechanism 452. The head transport mechanism 452 may transport the replacement lamination head 466 from the reload station 460 to a position within the series of lamination heads 152 previously occupied by the removed lamination head 468. The head-engaging beam 454 may then be translated vertically downward to bring the replacement lamination head 466 downward to the same level as the remaining lamination heads 152 within the lamination station 150 until the replacement lamination head 466 engages and is supported by the head support beam 456, which head support beam 456 may position the replacement lamination head 466 in alignment with (in line with) the series of lamination heads 152. The reloader engaging element 470 may then be laterally retracted.

Referring to fig. 40, an embodiment of a manufacturing system 100 having a reloading system 450 and a series of laminated heads 152 configured as head modules 170 is illustrated. The head modules 170 may be coupled to a single, common mounting frame 154. Each head module 170 may be configured similarly to the arrangement of head modules 170 shown in fig. 29 and described above. For example, each head module 170 in fig. 40 may have a frame coupling element 172 (e.g., a plate) to which a head component 220 (e.g., material supply roll 222, backing layer collection roll 300, material dispensing mechanism 260, etc.) is mounted. The frame coupling elements 172 of each head module 170 may include a head coupling element 156 mounted on top of the frame coupling elements 172, the head coupling element 156 being similar to the head coupling element 156 in fig. 37. In fig. 40, the frame coupling element 172 is configured to be removably attached to a single side (e.g., the first side 158 of the mounting frame 154), and the opposite side (e.g., the second side 160) of the mounting frame 154 may be free of the frame coupling element 172 and the head component 220.

In fig. 40, the mounting frame 154 of fig. 40 can be configured similar to the head support beam 456 shown in fig. 37-39 and described above. For example, the mounting frame 154 of fig. 40 may support a series of head modules 170 aligned with one another on the lamination surface 120 to lay up the composite laminate 400. Each head module 170 is independently removable from the mounting frame 154. As described above, the head transfer mechanism 452 may be configured to remove one of the head modules 170 from the mounting frame 154 by engaging the head coupling element 156 and translating the head module 170 upward. The head transport mechanism 452 may transport the removed head module 170 to a holding station 462 (e.g., fig. 34), retrieve the replacement head module 170 from the head holder 463 at a reloading station 460 (e.g., fig. 34), install the replacement head module 170 in the position previously occupied by the removed head module 170, and transport the removed head module 170 from the holding station 462 to the reloading station 460 for servicing, such as replacing the roll of material 224 on the removed head module 170 and/or servicing the head component 220 of the removed head module 170.

Referring to fig. 41-44, a series of top views of an embodiment of manufacturing system 100 is shown, wherein composite laminate 400 is laid down during translation of lamination surface 120 through lamination station 150 in first direction of travel 128, and wherein composite laminate 400 is simultaneously trimmed, after which lamination surface 120 and composite laminate 400 are translated in the opposite direction back through lamination station 150 in second direction of travel 130. For example, fig. 41 shows the initial position of the lamination mandrel 122 at the lamination surface origin position 134 after the lamination mandrel 122 has been moved laterally from the lamination surface preparation position 132 to the lamination surface origin position 134. Fig. 42 shows lamination mandrel 122 moving through lamination station 150 in first direction of travel 128 while composite laminate 400 is being laid up by lamination head 152. In one embodiment, the lamination head 152 may be limited to applying the paving material 228 to a lamination surface 120 moving in a single direction of travel (e.g., first direction of travel 128), and the lamination head 152 may not be able to apply the paving material 228 to the lamination surface 120 when moving in a second direction of travel 130 opposite the first direction of travel 128.

Alternatively, in an embodiment not shown, laminating head 152 may be limited to applying paving material 228 to laminating surface 120 moving along second direction of travel 130, and laminating head 152 may not be able to apply paving material 228 to laminating surface 120 moving along first direction of travel 128. In fig. 42, composite laminate 400 is shown being trimmed by trimming apparatus 312 as lamination mandrel 122 exits lamination station 150 and passes through trimming station 310 between lamination station 150 and lamination surface aft position 136, and simultaneous lamination and trimming of composite laminate 400 is shown. FIG. 43 shows lamination mandrel 122 in lamination surface aft position 136 and supporting composite laminate 400 in the trimmed state.

Fig. 44 shows the lamination mandrel 122 after translating back through the lamination station 150 to the lamination surface home position 134 along the second direction of travel 130. In some embodiments, as lamination mandrel 122 moves through lamination station 150 in second travel direction 130, lamination heads 152 may apply additional layup material 228 onto composite laminate 400, which may require one or more lamination heads 152 to have bi-directional layup capabilities as described below. In fig. 44, the lamination mandrel 122 may be laterally transferred from the lamination surface origin position 134 to the lamination surface unloading position 138 via a conveyor system (not shown) or a robotic system (not shown). With the lamination mandrel 122 in the lamination surface unloading position 138, the lamination mandrel 122 with composite laminate 400 may be unloaded to another manufacturing location or position for further processing, such as secondary trimming, compacting, forming, and/or curing, of the composite laminate 400. Alternatively, composite laminate 400 may be unloaded or removed from lamination mandrel 122, and lamination mandrel 122 may be cycled back to lamination surface preparation position 132. In some embodiments, prior to unloading, composite laminate 400 may be pre-equipped with materials and components used in post-processing of composite laminate 400. For example, the composite laminate 400 may be pre-equipped with any one or more of a peel ply layer, a release film, a breathable cloth, a pouched film, an air bladder, an edge sealant, a vacuum fitting, a tire membrane panel, a radius filler, and various other materials and/or components that may be used in any of a variety of post-processing operations.

Referring to fig. 45-48, a series of top views of an embodiment of manufacturing system 100 having laminating head 152 is shown, in some embodiments, laminating head 152 may be limited to dispensing paving material 228 along a single dispensing direction 204 (fig. 7). However, in an embodiment not shown, the lamination head (not shown) may have bi-directional layup capability, wherein the head component 220 is configured to dispense the layup material 228 in either of the opposite directions. In fig. 45-48, composite laminate 400 is translated through lamination station 150 in first direction of travel 128 without any lamination heads 152 applying layup material 228, after which lamination mandrel 122 is layed up while being translated back through lamination station 150 in second direction of travel 130. Composite laminate 400 is also shown being trimmed while moving away from lamination station 150 and toward lamination surface home position 134. Figure 45 shows the lamination mandrel 122 initially in the lamination surface home position 134. Fig. 46 shows the lamination mandrel 122 in the lamination surface back position 136 after passing through the lamination station 150 without any lamination heads 152 applying the layup material 228.

Fig. 47 shows lamination mandrel 122 moving in second travel direction 130 while lamination head 152 is applying layup material 228 to lay up composite laminate 400, which composite laminate 400 is being trimmed by trimming station 310 as lamination mandrel 122 moves away from lamination station 150 and toward lamination surface origin location 134. Fig. 48 shows the lamination mandrel 122 in the lamination surface unload position 138 after having been moved laterally from the lamination surface home position 134. Advantageously, the embodiment of the manufacturing system 100 of fig. 45-48 allows for loading and unloading of the lamination mandrel 122 at the same location (e.g., lamination surface home location 134), which may reduce the amount of factory floor space required to operate the manufacturing system 100 as compared to an arrangement in which the lamination mandrel 122 is loaded onto the manufacturing system 100 at one end of the manufacturing system 100 (e.g., at the lamination surface home location 134) and the lamination mandrel 122 is unloaded from the manufacturing system 100 at the opposite end of the manufacturing system 100.

Although the manufacturing system 100 in fig. 41-44, 45-48, and 51-54 includes a finishing station 310 at each of the opposite ends of the lamination station 150, the manufacturing system 100 may be limited to a single finishing station 310 located proximate one of the opposite ends of the lamination station 150. For example, the manufacturing system 100 may be provided with a single finishing station 310 located at one end of the lamination station 150 (the end located downstream of the end of the composite laminate 400 exiting the lamination station 150) such that finishing may occur simultaneously with the layup of the composite laminate 400. However, by providing a finishing station 310 at each opposing end of the lamination station 150, the manufacturing system 100 may operate in a manner that allows the composite laminate 400 to be laid on the lamination surface 120 moving along the first direction of travel and/or along the second direction of travel, and this may provide flexibility with respect to the location and/or orientation for installing the manufacturing system 100 within the manufacturing facility based on the available floor space and/or the production flow direction within the manufacturing facility.

Referring to fig. 49, an end view of an embodiment of the manufacturing system 100 is shown, the manufacturing system 100 being configured to move the lamination mandrel 122 laterally in an in-plane direction between a lamination surface preparation position 132, a lamination surface home position 134, and a lamination surface unload position 138. For example, the manufacturing system 100 may include a conveyor system (not shown) or a track system (not shown) and a linear actuator mechanism (not shown) to move the first lamination mandrel 122a in-plane from the lamination surface preparation position 132 to the lamination surface home position 134 prior to translating the first lamination mandrel 122a through the lamination station 150 for laying up and finishing the first composite laminate 400 a. After the first lamination mandrel 122 a/first composite laminate 400a have been returned to the lamination surface home position 134, the manufacturing system 100 (e.g., conveyor system, rail system-not shown) may be configured for in-plane movement of the first lamination mandrel 122 a/first composite laminate 400a from the lamination surface home position 134 to the lamination surface unload position 138, as shown in fig. 49, and the second lamination mandrel 122b may be moved to the lamination surface home position 134 prior to translation through the lamination station 150 for laying the second composite laminate 400b, while the first composite laminate 400a is unloaded from the first lamination mandrel 122a, followed by in-plane translation of the first lamination mandrel 122a to the lamination surface preparation position 132. The above process of alternately laying up composite laminate 400 on first lamination mandrel 122a and second lamination mandrel 120b may be repeated any number of times.

Referring to fig. 50, an end view of an embodiment of a manufacturing system 100 having a lamination surface origination position 134 and a lamination surface unloading position 138, but without a lamination surface preparation position 132, is shown. The manufacturing system 100 of fig. 50 may be configured to move the lamination mandrels 122 in a combination of in-plane and out-of-plane movements (e.g., vertical movements) using one or more of a variety of mechanisms including the conveyor systems (not shown), rail systems (not shown), autonomous vehicles (not shown) described above, and/or using an overhead gantry (not shown), robotic device (not shown), or other mechanism. After the first lamination mandrel 122a has passed through the lamination station 150 and the first composite laminate 400a has been laid and trimmed and the first lamination mandrel 122a has returned to the lamination surface home position 134, the first lamination mandrel 122 a/first composite laminate 400a can be moved laterally in an in-plane direction from the lamination surface home position 134 to the lamination surface unload position 138, as shown in fig. 50, the first composite laminate 400a can be unloaded from the first lamination mandrel 122a while the second lamination mandrel 122b is moved to the lamination surface home position 134 to lay up the second composite laminate 400b before passing the second lamination mandrel 122b through the lamination station 150, after which the second lamination mandrel 122 b/second composite laminate 400b is returned to the lamination surface home position 134. The second lamination mandrel 122 b/second composite laminate 400b may be moved laterally in an in-plane direction from the lamination surface home position 134 to the lamination surface unload position 138 while the first lamination mandrel 122a is lifted off the lamination surface unload position 138 and lowered to the lamination surface home position 134. The above process of alternately laying composite laminate 400 on two different lamination mandrels 122 may be repeated any number of times.

A technical effect of the arrangements shown in fig. 49-50 is that the rate at which composite laminate 400 is laid down can be increased by cycling multiple lamination mandrels 122 between the lamination surface home position 134, the lamination surface preparation position 132, and the lamination surface unload position 138 (fig. 49), or between the lamination surface home position 134 and the lamination surface unload position 138 (fig. 50). The selection between the arrangement of fig. 49 and the arrangement of fig. 50 may be based on the configuration of the production facility into which the manufacturing system 100 is to be installed, and may include consideration of various factors such as floor space limitations and/or vertical space constraints. In an embodiment not shown, the manufacturing system 100 may include a single lamination mandrel 122 for laying up the composite laminate 400, and it may include moving the lamination mandrel 122/composite laminate 400 from the lamination surface home position 134 to the lamination surface unload position 138 to unload the composite laminate, followed by moving the unloaded lamination mandrel 122 back to the lamination surface home position 134 in preparation for passing again through the lamination station 150 to lay up another composite laminate 400.

In any of the embodiments disclosed herein, the manufacturing system 100 can operate in a manner such that at least two (2) lamination mandrels 122 (e.g., first lamination mandrel 122a and second lamination mandrel 122 b) are shifted between two (2) or more positions, such as lamination surface origin position 134 and adjacent positions (e.g., lamination surface preparation position 132 and/or lamination surface unloading position 138). By operating the manufacturing system 100 with at least two (2) lamination mandrels 122 in the manner described above, the manufacturing system 100 may move one lamination mandrel 122 through the manufacturing system 100 (e.g., through the lamination station 150) for laying up a new composite laminate 400 while simultaneously clearing (e.g., unloading) the remaining lamination mandrels 122 of the just-completed composite laminate 400, which just-completed composite laminate 400 may be transported to another location (not shown) for further processing, such as secondary trimming, compaction, forming and/or curing.

Referring to fig. 51-54, a series of top views of an embodiment of a manufacturing system 100 is shown laying up a composite laminate 400 in an endless process during which a lamination mandrel 122 translates in a first direction of travel 128 through a lamination station 150 and bypasses the lamination station 150 during return to a lamination surface home position 134. For example, fig. 51 shows the initial position of the lamination mandrel 122 after having been moved laterally from the lamination surface preparation position 132 to the lamination surface home position 134. Fig. 52 shows the lamination mandrel 122 moving in the first direction of travel 128 through the lamination station 150 and the finishing station 310 toward the lamination surface back location 136. FIG. 53 shows lamination mandrel 122 in lamination surface aft position 136 and supporting composite laminate 400 in a trimmed condition. Figure 54 shows the lamination mandrel 122 returned to the lamination mandrel 122 original position after bypassing the lamination station 150. Although not shown, the manufacturing system 100 may include one or more conveyor systems, robotic devices, or other mechanisms as described above for transferring the lamination mandrel 122 from the lamination surface back location 136 to the lamination surface unloading location 138 while bypassing the lamination station 150. As described above, the manufacturing system 100 may be limited to a single finishing station 310 located near one of the opposite ends of the laminating station 150. For example, manufacturing system 100 may be limited to a single finishing station 310 located downstream of the exit of composite laminate 400 from lamination station 150.

Referring to fig. 55-58, a series of top views of an embodiment of manufacturing system 100 is shown laying up composite laminate 400 in an alternative endless process during which lamination mandrel 122 initially bypasses lamination station 150 while moving in first direction of travel 128 and composite laminate 400 is laid up and trimmed as lamination mandrel 122 moves through lamination station 150 in second direction of travel 130. Fig. 55 shows the initial position of the lamination mandrel 122 after having been moved from the lamination surface home position 134 to the lamination surface unload position 138. As described above with respect to fig. 51-54, the manufacturing system 100 may include one or more mechanisms, such as a conveyor system (not shown) and/or a robotic device (not shown), for transferring the lamination mandrel 122 from the lamination surface unloading location 138 to the lamination surface back location 136 while bypassing the lamination station 150.

Figure 56 shows the lamination mandrel 122 in the lamination surface back position 136 after bypassing the lamination station 150. Fig. 57 shows simultaneous lamination and trimming of composite laminate 400 during movement of lamination mandrel 122 in second direction of travel 130 through lamination station 150 and trimming station 310 toward lamination surface home position 134. Fig. 58 shows lamination mandrel 122 in lamination surface home position 134 and supporting composite laminate 400 in a trimmed condition. Advantageously, the above-described annular method of laying up composite laminate 400 as shown in fig. 51-54 and 55-58 may allow composite laminate 400 to be manufactured at relatively high manufacturing rates by increasing the frequency at which lamination mandrel 122 may be translated through lamination station 150.

As described above, one or more lamination heads 152 may have bi-directional layup capabilities, wherein the lamination heads 152 are capable of dispensing a layup material 228 onto the lamination surface 120 moving both along the first direction of travel 128 and along the second direction of travel 130. Advantageously, the bi-directional layup capability allows layup material 228 to be dispensed by the lamination head 152 as one or more lamination mandrels 122 traverse the lamination station 150 in both the first and second directions of

travel

128, 130, and it allows for layup of composite laminates 400 having greater laminate thicknesses in a shorter period of time than would be achievable if the lamination station 150 included a lamination head 152 limited to dispensing layup material 228 onto one or more lamination mandrels 122 moving in a single direction (e.g., only the first or second directions of travel 128, 130). Example lamination head 152 may be implemented in any of the manufacturing system 100 embodiments described above. Additionally, in some embodiments, the lamination head 152 may have self-threading capabilities, allowing the backing material 226 (e.g., the paving material 228 supported by the backing layer 230) to pass autonomously (e.g., without human intervention) through the lamination head 152, which may be required each time a new roll of material 224 is installed on the material supply roll 222. A lamination head 152 without bi-directional layup capability but with self-threading capability may be used in any of the manufacturing systems 100 disclosed herein. Likewise, a lamination head 152 without self-threading capability but with bi-directional laydown capability may be used in any of the manufacturing systems 100 disclosed herein.

Referring to fig. 59-62, an embodiment of a manufacturing system 100 is shown in which the lamination head 152 is configured to continuously dispense paving material 228 onto the lamination surface 120. Manufacturing system 100 includes one or more finishing devices 312, which finishing devices 312 are configured to periodically cut composite laminate 400 in the transverse direction to separate composite laminate 400 into end-to-end longitudinal segments 401. In fig. 59-62, the laminating surface 120 includes a series of laminating mandrels 122, the series of laminating mandrels 122 being disposed in end-to-end relationship with one another. The series of end-to-end lamination mandrels 122 may optionally be joined or coupled together, for example, via a mechanical coupling (not shown) between each pair of adjacent lamination mandrels 122. As noted above, the lamination mandrels 122 may be slightly spaced apart or may abut against each other. The manufacturing system 100 is configured for continuously laying up a composite laminate 400 on an end-to-end laminate mandrel 122. The one or more trimming devices 312 are configured to form a transverse cut 314 in the composite laminate 400 exiting the lamination station 150 and thereby separate the continuous composite laminate 400 into a series of end-to-end longitudinal segments 401. Fig. 59 is a top view of the manufacturing system 100 during an initial stage of the process of laying up the composite laminate 400, showing the lamination mandrel 122 moving along the base member 102 from the layup surface home position 134 into the lamination station 150. Additional lamination mandrels 122 may be mounted on the base member 102 in an end-to-end relationship that interfaces with each lamination mandrel 122 currently entering the lamination station 150.

For example, as shown in fig. 60, additional lamination mandrels 122 may be sequentially mounted on the base member 102 in an end-to-end relationship abutting one another for continuous movement through the lamination station 150. Fig. 60 also shows a portion of the composite laminate 400 supported on the lamination mandrel 122 exiting the lamination station 150. Further, a trimming device 312 is shown, the trimming device 312 being configured to move in a transverse direction relative to the longitudinal direction of the composite laminate 400 to form a transverse cut 314 in the composite laminate 400 to divide the composite laminate 400 into end-to-end longitudinal segments 401. Although fig. 60 shows finishing device 312 forming transverse cut 314 in composite laminate 400 at the location where a pair of lamination mandrels 122 butt against each other, transverse cut 314 may be formed at any location along composite laminate 400 in order to divide composite laminate 400 into longitudinal segments 401 of any length, regardless of the length of each individual lamination mandrel 122. Fig. 61 is a top view of the manufacturing system 100 showing one of the lamination mandrels 122 in the lamination surface back position 136 and showing the longitudinal segment 401 positioned on top of the lamination mandrel 122. The lamination mandrel 122 is also shown in phantom after being unloaded from the base member 102. Further, a longitudinal segment 401 of composite laminate 400 after unloading from lamination mandrel 122 is shown in phantom. Fig. 62 is a side view of the manufacturing system 100 showing the series of end-to-end lamination mandrels 122 moving through the lamination station 150 and showing the continuous layup of composite laminates 400 on the lamination mandrels 122.

In fig. 59-62, the longitudinal segments 401 may be sequentially unloaded from the laminating surface 120 as each longitudinal segment 401 reaches the laminating surface rear position 136. In one embodiment, each longitudinal segment 401 may be unloaded by a segment removal mechanism (not shown), such as a pick-and-place machine located at the rear of the lamination surface location 136. Alternatively, the longitudinal segments 401 may be unloaded using one or more robotic devices or any of a variety of other devices configured to lift each longitudinal segment 401 off of the lamination mandrel 122 for optional transport to another location for post-processing. In yet another embodiment, the longitudinal segments 401 may be unloaded manually using one or more technicians. After unloading the one or more longitudinal segments 401 supported on the lamination mandrel 122, the lamination mandrel 122 may be cycled back to the lamination surface home position 134 via a conveyor system (not shown), robotic devices and mechanisms (not shown), autonomous vehicles (not shown), manual transport, or other mechanisms, and may be reinstalled in line on the base member 102 behind the last lamination mandrel 122 on the manufacturing system 100.

In an embodiment not shown, one or more finishing devices 312 may be configured to form transverse cuts 314 to sever composite laminate 400 while laminate surface 120 continues to move composite laminate 400 along manufacturing system 100. Alternatively, the movement of the lamination surface 120 may be temporarily stopped to allow the trimming device 312 to move across the width of the composite laminate 400 to form the transverse cut 314. Although not shown, manufacturing system 100 may include additional finishing devices 312 configured to finish the side edges of composite laminate 400 before, during, or after composite laminate 400 is divided into longitudinal segments 401.

During lay-up of composite laminate 400 and/or during cutting and/or trimming of the composite laminate, composite laminate 400 may be secured to lamination mandrel 122 via vacuum pressure generated by vacuum pressure source 146 (fig. 62), which vacuum pressure source 146 is fluidly coupled to a plurality of holes 144 (fig. 6), which holes 144 may optionally be formed in an outer surface of lamination mandrel 122. As described above, a layer of peel ply (not shown) may be applied to lamination mandrel 122 prior to dispensing of paving material 228 by lamination head 152. Vacuum pressure may secure the peel ply layer to lamination mandrel 122 and layup material 228 may have a level of tackiness that causes it to adhere to the peel ply layer to prevent layup material 228 from shifting during dispensing onto lamination mandrel 122 and/or during cutting or trimming of composite laminate 400. Alternatively, the peel ply layer may be omitted and vacuum pressure may be applied directly to the first layer of layup material dispensed onto lamination mandrel 122.

Referring to fig. 63-66, another embodiment of a manufacturing system 100 configured for continuously laminating a composite laminate 400 is illustrated. The manufacturing system 100 has a series of laminating heads 152, the series of laminating heads 152 being stationarily positioned in end-to-end relationship with one another and defining a laminating station 150. Each lamination head 152 within the series is configured to dispense paving material 228 along the dispensing direction 204 (fig. 7). The manufacturing system 100 includes a laminating belt 124, the laminating belt 124 having an outer surface movable below the laminating station 150 in a direction generally aligned with the dispensing direction 204. The lamination head 152 is configured to sequentially apply the layup material 228 onto the outer surface of the lamination belt 124 and onto the previously applied layup material 228 as the outer surface of the lamination belt 124 moves through the lamination station 150, thereby forming a composite laminate 400 having a stack of composite plies arranged in a desired ply stack order defined by the position of the lamination head 152 relative to each other within the lamination station 150.

Manufacturing system 100 additionally includes one or more finishing devices 312, which finishing devices 312 are located downstream of lamination station 150 and are configured to periodically form transverse cuts 314 in composite laminate 400 to divide composite laminate 400 into longitudinal segments 401. FIG. 63 is a top view of the manufacturing system 100 prior to dispensing the paving material 228 onto the moving laminate strip 124. In some embodiments, one of the lamination heads 152 in the lamination station 150 may be configured to dispense a layer of protective peel ply onto the outer surface of the laminate tape 124 prior to dispensing the layup material 228 through the remaining lamination heads 152 in the lamination station 150. Similar to the alternative arrangement described above for the lamination mandrel 122, the lamination belt 124 can include a plurality of holes 144 (fig. 6), which holes 144 can be fluidly coupled to a vacuum pressure source 146 (fig. 66) for generating a vacuum force between the outer surface of the lamination belt 124 and the paving material 228 dispensed by the lamination head 152. The vacuum force may secure the peel ply layer to the laminate tape 124, and the layup material 228 may adhere to the peel ply layer, thereby preventing the composite laminate 400 from shifting relative to the laminate tape 124 during the process of laying, trimming and/or cutting the composite laminate 400.

Fig. 64 is a top view of manufacturing system 100 illustrating continuous laying up of composite laminate 400 within lamination station 150 and illustrating a portion of composite laminate 400 after exiting lamination station 150. A finishing assembly 312 is also shown forming a transverse cut 314 in composite laminate 400 to divide composite laminate 400 into end-to-end longitudinal segments 401. As described above with respect to the manufacturing system 100 embodiment shown in fig. 59-62, one or more finishing devices 312 in the manufacturing system 100 of fig. 63-66 may be configured to transversely cut the composite laminate 400 while temporarily halting movement of the laminate belt 124, after which the laminate belt 124 may be restarted. Alternatively, one or more finishing devices 312 may be configured to form the transverse cut 314 while the laminate strip 124 continues to move, as described above. In addition to forming transverse cut 314, manufacturing system 100 may include one or more finishing devices 312, where finishing devices 312 are configured to finish composite laminate 400, such as finishing a side edge or other portion of composite laminate 400.

Fig. 65 is a top view of the manufacturing system 100, illustrating the location of a transverse cut 314 formed in the composite laminate 400 by the trimming device 312, the transverse cut 314 dividing the composite laminate 400 into longitudinal segments 401. The longitudinal section 401 is also shown in dashed lines after unloading from the laminate tape 124. Each longitudinal segment 401 may be unloaded using a robotic device (not shown), a conveyor system (not shown), manually, or using any of a variety of other devices. Fig. 66 is a side view of the manufacturing system 100, illustrating the continuous laying up of composite laminate 400 on laminate tape 124.

Although the lamination station 150 of fig. 59-66 includes a lamination head 152 that is vertically movable as a unit during dispensing of the paving material 228, any of the manufacturing system 100 embodiments may include a lamination head 152 that is configured with a vertically movable and/or removable head module 170 similar to that described above and/or shown in fig. 29-33. Alternatively or additionally, any of the manufacturing system 100 configurations of fig. 59-66 may include the ability to rotate one or more lamination heads 152 as described above and/or as shown in fig. 14, 16-21 to allow for rapid replacement of lamination heads 152, head modules 170, and/or rapid replacement of rolls of material 224 and/or to allow for maintenance of either lamination heads 152 or head modules 170 without interrupting lamination of composite laminate 400. Advantageously, the ability to continuously lay up composite laminate 400 on a moving series of end-to-end lamination mandrels 122 or lamination belts 124 maximizes the throughput of manufacturing system 100.

Referring to fig. 67, a flow chart of operations included in a method 500 of manufacturing a composite laminate 400 is shown. Step 502 includes dispensing a paving material 228 along the dispensing direction 204 from a plurality of laminating heads 152 that are stationarily positioned in end-to-end relationship with one another and define a laminating station 150 (e.g., fig. 1-6). As described above, each lamination head 152 has the head part 220, and the head part 220 includes: at least one material supply roll 222 configured to support a roll 224 of backing material 226; at least one material dispensing mechanism 260 configured to receive backing material 226 from material supply roll 222 and separate backing layer 230 from paving material 228; and at least one backing layer collection roller 300 configured to take up backing layer 230 after separation from paving material 228. One or more lamination heads 152 (e.g., fig. 1-7) in lamination station 150 may be configured to dispense a paving material 228 onto a lamination surface 120 moving in a single direction of travel (e.g., first direction of travel 128 or second direction of travel 130). Alternatively, one or more of the laminating heads 152 in the laminating station 150 may have bi-directional layup capability for dispensing a layup material 228 onto the laminating surface 120 moving in both the first direction of travel 128 and the second direction of travel 130, as described below.

Step 504 of the method 500 includes moving the lamination surface 120 under the lamination station 150 in a direction aligned with the dispensing direction 204 (fig. 7) of the lamination head 152. The lamination surface 120 moves between a lamination surface home position 134 and a lamination surface back position 136. As described above, the laminating surface 120 may move in a linear direction as shown. Alternatively, in embodiments not shown, the laminating surface 120 may move in a non-linear direction, such as in an arc. The lamination heads 152 may be arranged complementary to the linear or non-linear direction of movement of the lamination surface 120 so as to lay down composite plies 400 having a linear shape (e.g., a straight shape) or a non-linear shape (e.g., an arcuate shape), respectively.

The step 504 of moving the lamination surface 120 under the lamination station 150 may include translating one or more rigid lamination mandrels 122 (e.g., fig. 1-4) in at least one direction (e.g., along the first direction of travel 128 and/or along the second direction of travel 130) under the lamination head 152 while applying the layup material 228 to the outer surface of the one or more lamination mandrels 122 and/or to a layup material 228 previously applied to the lamination mandrel 122. As described above, in embodiments, the method may include moving a series of lamination heads 152 in at least one direction, the series of lamination heads 152 being arranged in spaced end-to-end relationship with each other or in abutting end-to-end relationship with each other (fig. 59-62). For example, a series of lamination mandrels 122 may be coupled end-to-end and may be spaced up to several inches apart from each other, and composite laminate 400 may be laid up on each of the series of lamination mandrels 122 continuously moving through lamination station 150.

In an alternative embodiment, the step 504 of moving the laminating surface 120 below the laminating station 150 can include moving the continuous annular laminating belt 124 (e.g., FIG. 5) below the laminating head 152 while applying the paving material 228 to the outer surface of the laminating belt 124 and/or to paving material 228 previously applied to the outer surface of the laminating belt 124. In some embodiments, the manufacturing system 100 may be configured such that the lamination surface 120 (e.g., lamination mandrel 122) may be moved from the lamination surface preparation position 132 (e.g., fig. 41, 45, 51, 55) to the lamination surface home position 134 prior to passing through the lamination station 150 for laying up the composite laminate 400. By positioning the lamination mandrel 122 in the lamination surface preparation position 132, after completion of a composite laminate 400 on the lamination mandrel 122 previously occupying the lamination surface home position 134, the lamination mandrel 122 may be quickly moved to the lamination surface home position 134 to begin laying up a new composite laminate 400.

Translating the one or more lamination mandrels 122 in at least one direction under the lamination head 152 can include passing the one or more lamination mandrels 122 through the lamination station 150 twice. For example, as shown in fig. 41-44 and 45-48, the method may include translating the lamination mandrel 122 in the first direction of travel 128 from the lamination surface origin position 134 through the lamination station 150 to the lamination surface back position 136, then translating the lamination mandrel 122 in the second direction of travel 130 from the lamination surface back position 136 back through the lamination station 150 to the lamination surface origin position 134, and applying the layup material 228 to the lamination surface 120 during translation of the lamination mandrel 122 in the first direction of travel 128 and/or in the second direction. Fig. 41-44 illustrate an embodiment in which composite laminate 400 is laid up and trimmed as lamination mandrel 122 moves in first direction of travel 128 from lamination surface home position 134 to lamination surface aft position 136, while no laying up or trimming occurs as lamination mandrel 122 moves in second direction of travel 130 from lamination surface aft position 136 back through lamination station 150 to lamination surface home position 134.

Fig. 45-48 illustrate an embodiment in which the lamination mandrel 122 is moved in the first direction of travel 128 through the lamination station 150 without layup or trimming occurring, after which the composite laminate 400 is layup and trimmed as the lamination mandrel 122 is moved in the second direction of travel 130 from the lamination surface back position 136 to the lamination surface home position 134. In another embodiment, not shown, composite laminate 400 may be laid as lamination mandrel 122 passes through lamination station 150 in first direction of travel 128, and additional layup material 228 may be applied to composite laminate 400 as lamination mandrel 122 passes back through lamination station 150 in second direction of travel 130.

In still other embodiments of the method, translating the lamination mandrel 122 in at least one direction under the lamination head 152 may include a single pass of one or more lamination mandrels 122 through the lamination station 150. For example, as shown in fig. 51-54, the method may include translating one or more lamination mandrels 122 in a first direction of travel 128 from a lamination surface origin position 134 through a lamination station 150 and to a lamination surface back position 136, and applying a layup material 228 to the lamination surface 120 during the translation through the lamination station 150, followed by translating the one or more lamination mandrels 122 from the lamination surface back position 136 to the lamination surface origin position 134 while bypassing the lamination station 150. In fig. 51-54, trimming of composite laminate 400 may be performed as one or more lamination mandrels 122 exit lamination station 15 while one or more lamination mandrels 122 are moved in first direction of travel 128 toward lamination surface back location 136.

Fig. 55-58 illustrate an embodiment in which the lamination mandrel 122 is moved from the lamination surface home position 134 to the lamination surface back position 136 while bypassing the lamination station 150, then the lamination mandrel 122 is translated in the second direction of travel 130 from the lamination surface back position 136 through the lamination station 150 to the lamination surface home position 134, and a layup material 228 is applied to the lamination surface 120 during the translation through the lamination station 150. In fig. 55-58, trimming of composite laminate 400 may be performed as lamination mandrel 122 exits lamination station 150 while lamination mandrel 122 is moved in second direction of travel 130 toward lamination surface home position 134. In any of the presently disclosed manufacturing system 100 embodiments having finishing stations 310 located at each of the opposite ends of lamination station 150, finishing device 312 may be configured to finish composite laminate 400 as composite laminate 400 exits lamination station 150 while composite laminate 400 is moving in first direction of travel 158, and then finish composite laminate 400a second time after composite laminate 400 passes through and exits lamination station 150 while composite laminate 400 reverses direction and moves in second direction of travel 160.

Step 506 of method 500 includes sequentially applying a layup material 228 from any one or more of the lamination heads 152 onto the lamination surface 120 and onto the previously applied layup material 228 as the lamination surface 120 passes through the lamination station 150, thereby forming a composite laminate 400 having a stack of plies 402 arranged in a desired ply stacking order 410. As described above with respect to fig. 8-9, the lamination head 152 is arranged to sequentially apply the layup material 228 according to the ply stacking order 410. In this regard, each lamination head 152 in the series is dispensed and loaded with a layup material 228, the layup material 228 having a material configuration 406 corresponding to a ply stacking sequence 410 of the composite laminate 400 to be manufactured (fig. 8). As shown in fig. 8-9, the ply stacking sequence 410 of composite laminate 400 is defined by the relative position of lamination head 152 within lamination station 150. However, composite laminate 400 may be formed with one or more of lamination heads 152 deactivated (i.e., without dispensing paving material 228) along at least a portion of the total length of composite laminate 400.

In this regard, the step 506 of sequentially applying the paving material 228 from one or more of the laminating heads 152 may include independently starting, independently stopping, and/or independently restarting the application of the paving material 228 by any one of the laminating heads 152 while continuing the application of the paving material 228 by one or more of the other laminating heads 152 within the laminating station 150. For example, fig. 11 shows head No. 2 (fig. 8) momentarily stopping and then restarting application of paving material 228 while the remaining lamination heads 152 continuously apply paving material 228, which results in gaps 404 being formed in plies 2 (e.g., partial plies) of composite laminate 400 and in laminate thickness varying or not constant along the length of composite laminate 400. In another embodiment not shown, any one or more of the lamination heads 152 may intentionally delay the start of dispensing the paving material 228 after the remaining lamination heads 152 have started dispensing the paving material 228. For example, composite laminate 400 may be laid up with head No. 1 initially delaying temporarily the start of dispensing of paving material 228 onto lamination surface 120 while the remaining lamination heads 152 (e.g., heads No. 2-10) begin dispensing paving material 228 at a common location on lamination surface 120 moving through lamination station 150. In yet another embodiment, not shown, composite laminate 400 may be laid up with one or more of lamination heads 152 deactivated and no paving material 228 dispensed during the entire time composite laminate 400 is laid up, and resulting in composite laminate 400 having a reduced number of plies 402 similar to composite laminate 400 of fig. 13, which contains a total of five (5) plies 402.

Referring briefly to fig. 12-13, the step 506 of sequentially applying the paving material 228 from one or more of the laminating heads 152 can include applying the paving material 228 from at least one of the laminating heads 152, the paving material 228 having a material width 408 that is different than the material width dispensed by at least one other laminating head 152 in the laminating station 150. As described above, one or more lamination heads 152 may be loaded with a roll 224 of paving material 228, the paving material 228 having a different material width than the paving material 228 loaded onto the other lamination heads 152. For example, the layup material 228 loaded onto one or more of the lamination heads 152 may be a pre-cut prepreg strip having a reduced material width 408 relative to the material width 408 on the other lamination heads 152. In the embodiment of fig. 12-13, the series of lamination heads 152 is loaded with a layup material 228 having a material width 408, the material width 408 being arranged such that the lamination heads 152 lay up the uncured composite laminate 400 with the beveled side edges 414 on the side edges 414 of the composite laminate 40. The lamination heads 152 within the lamination station 150 may be aligned with each other such that the centerlines (not shown) of the paving materials 228 dispensed by the lamination heads 152 coincide, resulting in a composite laminate 400 having a transverse cross-section that is symmetrical about a vertical axis (not shown). However, one or more of lamination heads 152 may be laterally offset from other lamination heads 152 such that the centerline of paving material 228 dispensed by lamination head 152 is laterally offset from the centerline of paving material 228 dispensed by other lamination heads 152 and results in composite laminate 400 having an asymmetric lateral cross-section.

In some embodiments, the material width 408 of the layup material 228 loaded onto the lamination head 152 may be selected such that the side edges 414 are formed at a desired bevel angle 416 when the finished composite laminate 400 is viewed in transverse cross-section. For example, in fig. 12, the material width 408 of the composite laminate 400 comprising ten (10) plies 402 is such that the side edges 414 of the composite laminate 400 are each formed at an oblique angle 416 of about 20 degrees. Fig. 13 shows an embodiment of a composite laminate 400 that contains only five (5) plies 402 and produces a bevel 416 of approximately 10 degrees on each side edge 414. In an embodiment not shown, the material width 408 of the paving material 228 loaded onto the lamination head 152 may be selected such that the side edges 414 have a non-linear shape when the composite laminate 400 is viewed in transverse cross-section.

Step 508 of method 500 includes finishing composite laminate 400 using one or more finishing devices 312. As described above, manufacturing system 100 may include one or more finishing devices 312 defining at least one finishing station 310. For example, fig. 1-2 illustrate a manufacturing system 100 having a finishing station 310 located at each of the opposite ends of the laminating station 150. Trimming of the composite laminate 400 may include trimming at least one side edge 414 of the composite laminate 400. The trimming may be performed during movement of the lamination surface 120 from the lamination station 150 to the lamination surface back position 136, as shown in fig. 42, and/or may occur during movement of the lamination surface 120 from the lamination station 150 to the lamination surface home position 134, as shown in fig. 47. Step 508 of trimming composite laminate 400 may include trimming composite laminate 400 using one or more ultrasonic blades, laser devices, mechanical cutter blades, or any of a variety of other cutting mechanisms. The finishing device 312 may be configured to cut at least one side edge 414 of the composite laminate 400 as an oblique cut oriented non-perpendicular to the lamination surface 120 or a perpendicular cut oriented perpendicular to the lamination surface 120. However, as noted above, finishing device 312 may operate in any of a variety of geometric features formed in composite laminate 400 and is not limited to forming oblique or perpendicular cuts on side edges 414 of composite laminate 400.

After completing lay-up and finishing of composite laminate 400, the method may include moving lamination mandrel 122 from lamination surface origin position 134 to lamination surface unload position 138, as shown in fig. 44 and 48. Moving the lamination mandrel 122 to the lamination surface unloading position 138 may allow another lamination mandrel 122 to be moved to the lamination surface home position 134 to allow another composite laminate 400 to be laid up and trimmed while the just-completed composite laminate 400 is further processed or unloaded at the lamination surface unloading position 138. Referring briefly to fig. 49, in some embodiments, the method can include laterally moving at least two (2) lamination mandrels 122 in an in-plane direction between a lamination surface preparation position 132, a lamination surface home position 134, and a lamination surface unload position 138.

In an alternative embodiment, fig. 50 illustrates the out-of-plane movement of two (2) lamination mandrels 122 between a lamination surface home position 134 and a lamination surface unload position 138. Advantageously, the use of at least two (2) lamination mandrels 122 allows at least one lamination mandrel 122 to pass through the lamination station 150 for laying up the composite laminate 400 while the remaining lamination mandrels 122 are processed at the lamination surface unloading location 138. As described above, processing the lamination mandrel 122 at the lamination surface unloading location 138 may include removing the just-completed composite laminate 400 from the lamination mandrel 122 and/or pre-assembling the composite laminate 400 with materials and/or components that may be needed to further process (e.g., secondary trim, densifying, forming, and/or curing) the composite laminate 400 at another location (not shown).

Referring to fig. 16-28, the method may include moving (e.g., autonomously) one or more lamination heads 152 to a material reload location 208 to allow for servicing of the lamination heads 152, such as replacing depleted rolls of material 224, performing maintenance on the head components 220, or for other purposes. Lamination head 152 may be moved to material reload location 208 at any point in time before, during, or after the layup of composite laminate 400 for material replenishment or maintenance. For example, as described below, one or more lamination heads 152 in the lamination station 150 may be moved to the material reload position 208 to allow for servicing of the head components 220 on one side of the lamination head 152 while the opposite side of the lamination head 152 at the material application position 206 dispenses the paving material 228 along with the remaining lamination heads 152 in the lamination station 150. As described above, in some embodiments, one or more lamination heads 152 (e.g., fig. 6) within the lamination station 150 may have laterally opposite sides including a first side 158 and a second side 160. The first side 158 may have a first laminate assembly 200 of header components 220 and the second side 160 may have a second laminate assembly 202 of header components 220. As described above, the head member 220 on the first side 158 and the head member 220 on the second side 160 may be mounted to the mounting frame 154.

Referring to fig. 16-19, the method may include moving the second side 160 to a material application location 206, the material application location 206 being aligned with the dispensing direction 204 of the remaining lamination heads 152 within the lamination station 150. At material application location 206, second side 160 may dispense paving material 228 onto laminating surface 120 or onto previously applied paving material 228. Moving the second side 160 to the material application location 206 may result in moving the first side 158 to the material reload location 208 to allow for replacement of a roll 224 of material on the material supply drum 222 on the first side 158 and/or for maintenance of the first side 158. As an alternative to moving the second side 160 of the laminating head 152 to the material application position 206, the method may include moving the first side 158 of the laminating head 152 to the material application position 206 aligned with the dispensing direction 204 of the remaining laminating heads 152 within the laminating station 150, and moving the second side 160 to the material reload position 208, for example, for replacing a roll of material 224 on the second side 160 and/or for performing maintenance on the second side 160.

Still referring to fig. 16-19, moving the first side 158 or the second side 160 to the material application location 206 while moving the remaining one of the first side 158 or the second side 160 to the material reload location 208 may comprise independently rotating the lamination heads 152 an amount of 180 degrees about the vertical axis 174 to position the first side 158 or the second side 160 at the material application location 206 while positioning the remaining one of the first side 158 or the second side 160 at the material reload location 208. For example, fig. 17 illustrates rotation of the lamination head 152 about a vertical axis 174 (fig. 14). For lamination heads 152 spaced relatively close proximity to each other, it may be necessary to laterally translate the lamination heads 152 out of alignment with the remaining lamination heads 152 in the lamination station 150 to provide clearance for the rotating lamination heads 152. In this regard, the lamination heads 152 may be translated horizontally and/or vertically out of alignment with the remaining lamination heads 152, thereby providing space for rotating the lamination heads 152. However, in other embodiments, the lamination heads 152 within the lamination station 150 may be spaced apart from each other by a distance that allows each lamination head 152 to rotate 180 degrees about the vertical axis 174 without contacting adjacent lamination heads 152 and without requiring the lamination heads 152 to translate horizontally or vertically out of alignment with the remaining lamination heads 152.

Fig. 16 illustrates one of the lamination heads 152 being laterally translated out of alignment with the remaining lamination heads 152 prior to rotating the lamination heads 152 an amount of 180 degrees as illustrated in fig. 17. In an embodiment, the lamination head 152 may be laterally translatable along the beam 108 supporting the lamination head 152, as shown in fig. 14. After rotation, fig. 18 shows the lamination heads 152 laterally translated back into alignment with the remaining lamination heads 152 in the lamination station 150. Instead of the lamination heads 152 translating laterally to provide clearance for rotating the lamination heads 152, fig. 20-21 illustrate an embodiment in which the lamination heads 152 are raised vertically out of alignment with the remaining lamination heads 152 to allow clearance for rotating the lamination heads 152, after which the lamination heads 152 may be lowered vertically back into alignment with the remaining lamination heads 152. In the illustrated embodiment, the cross beam 108 may be vertically translatable along the pair of struts 106 that support the cross beam 108.

Referring to fig. 22-28, in yet another embodiment, the step of moving the first side 158 or the second side 160 of the lamination head 152 to the material application position 206 while moving the remaining one of the first side 158 or the second side 160 to the material reload position 208 may include rotating the lamination head 152 an amount of 180 degrees about a horizontal axis 176 oriented parallel to the series of lamination heads 152. As described above, the laminating head 152 may be mounted in series to a horizontal shaft 176, which horizontal shaft 176 may be supported at opposite ends by a pair of shaft supports 178. The manufacturing system 100 may include one or more motors (not shown) controlled by the controller 110 to independently rotate any one or more lamination heads 152 to position the first side 158 or the second side 160 at the material reload location 208 for replacing the roll of material 224 or for performing maintenance on the head assembly 220. In any of the embodiments disclosed herein, rotating the lamination head 152 to position the first side 158 or the second side 160 in the material reload position 208 may provide improved physical access to the head component 220 at that side of the material reload position 208.

Referring to fig. 29-33, some embodiments of the method may include replacing the head module 170 on the first side 158 and/or the second side 160 of the lamination head 152. In the embodiment of fig. 29, the lamination head 152 includes a mounting frame 154 having a head module 170 removably coupled to the first side 158 and a head module 170 removably coupled to the second side 160. As described above, each head module 170 includes a frame coupling element 172 (e.g., a plate or frame), to which frame coupling element 172 a head component 220 may be mounted. In this arrangement, the method may further include replenishing the roll of material 224 or removing and replacing the head module 170 on one of the first side 158 or the second side 160 of the mounting frame 154 while dispensing the paving material 228 from the head module 170 on the remaining one of the first side 158 or the second side 160 of the mounting frame 154. For example, as described above and shown in fig. 30-33, the lamination head 152 may be rotated 180 degrees about the vertical axis 174 (fig. 7) as a means of positioning the first side 158 or the second side 160 at the material application location 206 while positioning the remaining one of the first side 158 or the second side 160 at the material reload location 208.

Fig. 30 shows the lamination heads 152 translated horizontally out of alignment with the remaining lamination heads 152 in the lamination station 150. Fig. 31 shows the lamination head 152 rotated 180 degrees about the vertical axis 174. Fig. 32 illustrates the removal of the head module 170 from the mounting frame 154 of the lamination head 152 and the installation of a replacement head module 170 on the mounting frame 154 prior to the horizontal translation of the lamination head 152 back into alignment with the remaining lamination heads 152 illustrated in fig. 33. The head module 170 in the material reload position 208 facing away from the series of laminating heads 152 may allow physical access for removing the head module 170 as may be required if the roll of material 224 is depleted, for performing maintenance on the head component 220, or for replacing the current head module 170 with a head module 170 configured to dispense a different type of paving material 228. Replacement of the head module 170 may be performed manually, or replacement of the head module 170 may be performed autonomously, such as by a reloading system 450 as described below and shown in fig. 40.

Referring to fig. 29, in some embodiments, the head modules 170 on one or both sides of the mounting frame 154 may be vertically movable. For example, the head modules 170 on each of the first side 158 and the second side 160 of the mounting frame 154 of the lamination head 152 may be vertically movably coupled to the mounting frame 154. In the illustrated embodiment, the frame coupling element 172 of each head module 170 has a vertical member 180 configured to be vertically slidable within vertical grooves 182 included on each opposing side of the mounting frame 154. In such an arrangement, the method may include allowing the head modules 170 on the first side 158 and/or the second side 160 to move vertically in concert with starting and stopping dispensing paving material 228, and preventing the head modules 170 on the remaining one of the second side 160 and the first side 158 from moving vertically to allow for servicing of the head modules 170. In the embodiment of fig. 29, head module 170 on second side 160 is shown in upper position 184, while head module 170 on first side 158 may move vertically in unison with the start and stop of paving material 228 from head module 170 on first side 158.

As described above, the head module 170 in the material reload position 208 may be locked in the upper position 184 to prevent movement of any head components 220, thereby allowing a technician to service the head module 170. In this regard, while the head module 170 in the material application position 206 is activated and/or capable of dispensing paving material 228, the head module 170 in the material reload position 208 may be deactivated or unpowered. As described above, the lamination head 152 may be configured to autonomously electrically disconnect the head module 170 at the side rotated to the material reload position 208 (e.g., disconnect power and/or control signals to the head module 170) and autonomously electrically connect the head module 170 at the side rotated to the material application position 206. As described above, a technical effect of servicing the head module 170 in the material reloading position 208 while allowing the head module 170 in the material application position 206 to continue dispensing paving material 228 is to avoid downtime of the laminating head 152 that would otherwise occur if the laminating head 152 were to stop functioning. In this regard, the above-described arrangement shown in fig. 29 minimizes downtime of the manufacturing system 100, thereby maximizing throughput. Additionally, the removability of the head modules 170 provides flexibility with respect to quickly replenishing or replacing rolls 224 of material and/or quickly replacing head modules 170 having differently configured head components 220 to dispense different types of paving material 228.

Referring to fig. 34-39, in some embodiments, the method may include removing and replacing one of the lamination heads 152 from the lamination station 150 using the head transport mechanism 452 of the reload system 450. As described above, the reloading system 450 may include a head transfer mechanism 452 that is movable in a longitudinal direction of the manufacturing system 100. In addition, as shown in fig. 34-35, the reload system 450 may include one or more head holders 463 configured to hold the laminating heads 152. For example, the reload system 450 may include a reload station 460 having a head holder 463 for holding a replacement laminating head 466 (fig. 36). Additionally, the reloading system 450 may include a holding station 462 having a head holder 463 for holding the removed lamination heads 468.

As shown in fig. 38, the method can include removing one of the lamination heads 152 from the series of lamination heads 152 using a head transfer mechanism 452. For example, fig. 37-39 illustrate the head-engaging beams 454 extending laterally outward and engaging the head coupling elements 156 of the lamination heads 152 to vertically lift the lamination heads 152 out of alignment with the remaining lamination heads 152, as shown in fig. 39. As shown in fig. 34, the method may include transporting the removed lamination head 468 to a head holder 463 at a holding station 462, retrieving a replacement lamination head 466 from the head holder 463 at a reloading station 460, transporting the replacement lamination head 466 to a position previously occupied by the removed lamination head 468, and installing the replacement lamination head 466 in place of the removed lamination head 468. The head transport mechanism 452 may then transport the removed lamination head 468 from the holding station 462 to the reloading station 460, where the removed lamination head 468 may be serviced, which may include replacing the roll of material 224 on the material supply roll 222, performing maintenance or other operations on the head component 220, at the reloading station 460.

Referring to fig. 40, in the above embodiment, the laminating station 150 may include a plurality of head modules 170 coupled to the common mounting frame 154 by frame coupling members 172 (e.g., plates). Each head module 170 may include a frame coupling element 172 with a head component 220 mounted to the frame coupling element 172. The frame coupling element 172 of each head module 170 may be removably connected to the mounting frame 154. The method may include removing and/or replacing one or more head modules 170 using a reloading system 450 similar to that described above with respect to fig. 34-39. For example, the head transport mechanism 452 of the head module 170 reloading system 450 may be configured to engage and vertically lift the frame coupling element 172 of one of the head modules 170 out of alignment with the remaining head modules 170, transport the removed head module 170 to the holding station 462, retrieve the replacement head module 170 from the reloading station 460, transport the replacement head module 170 to the position previously occupied by the removed head module 170, and vertically lower the replacement head module 170 into alignment with the remaining head modules 170 of the laminating station 150. The head transfer mechanism 452 may transport the removed head module 170 from the holding station 462 to the reloading station 460 for servicing. Advantageously, the ability to autonomously remove and replace the lamination heads 152 or head modules 170 allows for continuous lay-up of the composite laminate 400 while servicing the removed lamination heads 468 or removed head modules 170.

Referring to fig. 59-66, in some embodiments, the step 506 of applying the paving material 228 from one or more lamination heads 152 may include continuously applying the paving material 228 from the lamination heads 152 onto the lamination surface 120. For example, in fig. 59-62, the method may include continuously applying a layup material 228 onto the series of end-to-end lamination mandrels 122 to form a continuous composite laminate 400, as described above. In fig. 63-66, the method may include continuously applying a paving material 228 onto a laminating belt 124 continuously moving under a laminating station 150. In such embodiments, the step 508 of trimming the composite laminate 400 may include forming at least one transverse cut 314 in the composite laminate 400 using one or more trimming devices 312 to divide the composite laminate 400 into end-to-end longitudinal segments 401. As described above, movement of lamination surface 120 (e.g., a series of lamination mandrels 122, lamination strips 124) may either be temporarily stopped to allow finishing device 312 to cut the composite laminate, or finishing device 312 may be configured to cut composite laminate 400 while moving. For the embodiments shown in fig. 59-66, the method may additionally include sequentially unloading the longitudinal segments 401 from the laminating surface 120 (e.g., fig. 57 and 61) using an automated mechanism or device (not shown), or by manually unloading the longitudinal segments 401. For the embodiment of fig. 59-62, the method may include recirculating each lamination mandrel 122 from the lamination surface back location 136 back to the lamination surface home location 134, whereby each lamination mandrel 122 may be installed after the last lamination mandrel 122 in the series prior to entering the lamination station 150.

In any of the manufacturing system 100 embodiments disclosed herein, the method may include securing the composite laminate 400 to the lamination surface 120 using vacuum pressure generated at the plurality of holes 144 (fig. 6) formed in the outer surface of the lamination surface 120. For example, as described above, the apertures 144 may be fluidly coupled to a vacuum pressure source 146 (e.g., fig. 62 and 66), which, upon command by the controller 110 (fig. 2), may generate a vacuum pressure at least before or during dispensing of the layup material 228 from the lamination head 152 as the lamination surface 120 (e.g., one or more of the lamination mandrel 122, the outer surface of the lamination band 124) passes through the lamination station 150. Such vacuum pressure may directly or indirectly (e.g., via a peel ply) secure composite laminate 400 in place on lamination surface 120, at least during lay-up of composite laminate 400 and optionally during trimming (e.g., fig. 42, fig. 47, fig. 52, and fig. 57) and/or cross cutting (e.g., fig. 60 and fig. 64) of composite laminate 400.

Furthermore, the present disclosure includes embodiments described in the following enumerated paragraphs:

A1. a manufacturing system 100, comprising: a plurality of laminating heads 152 stationarily positioned in end-to-end relationship with one another and defining a laminating station 150, each laminating head 152 configured to dispense a paving material 228 along a dispensing direction 204; a lamination surface 120 movable below the lamination station 150 in a direction generally aligned with the dispensing direction 204 between a lamination surface home position 134 and a lamination surface back position 136, the lamination head 152 being configured to sequentially apply a layup material 228 onto the lamination surface 120 and onto the previously applied layup material 228 as the lamination surface 120 passes through the lamination station 150, thereby forming a composite laminate 400 having a stack of composite plies 402 arranged in a desired ply stacking sequence defined by the positions of the lamination heads 152 relative to each other within the lamination station 150; one or more finishing devices 312 located proximate at least one of the opposite ends of the lamination station 150 and configured to finish the composite laminate 400 during at least one of: during the movement of the lamination surface 120 from the lamination station 150 to the lamination surface home position 134; and during the movement of the laminating surface 120 from the laminating station 150 to the laminating surface rear position 136.

A2. The manufacturing system 100 of A1, wherein: the at least one finishing device 312 is configured as at least one of an ultrasonic blade, a laser device, and a mechanical cutter blade.

A3. The manufacturing system 100 of a1 or A2, wherein the lamination surface 120 comprises one of: an outer surface of at least one continuous annular laminating belt 124, the at least one continuous annular laminating belt 124 being movable under the laminating head 152; an outer surface of the at least one rigid lamination mandrel 122, the at least one rigid lamination mandrel 122 translatable under the lamination head 152.

A4. The manufacturing system 100 of a3, wherein: the laminating head 152 is configured to continuously dispense paving material 228 onto the outer surface of the laminating surface 120; and one or more finishing devices 312 are configured to periodically cut the composite laminate 400 in the transverse direction to separate the composite laminate (400) into end-to-end longitudinal segments 401.

A5. The manufacturing system 100 of A3 or A4, the manufacturing system 100 further comprising: a vacuum pressure source 146; the lamination surface 120 has a plurality of apertures 144 fluidly coupled to a vacuum pressure source 146; and the vacuum pressure source 146 is configured to generate vacuum pressure at the outer surface to secure composite laminate 400 to the outer surface at least during application of paving material 228 onto the outer surface or onto paving material 228 previously applied to the outer surface.

A6. The manufacturing system 100 of any one of a1 to A5, wherein: the lamination heads 152 each include laterally opposite sides including a first side 158 and a second side 160, the first side 158 and the second side 160 each having a head member 220; and the first side 158 of the at least one lamination head 152 is movable to the material application position 206 aligned with the dispensing direction 204 to apply the paving material 228 to the lamination surface 120 while the second side 160 is moved to the material reload position 208 to service the second side 160 of the lamination head 152; and the second side 160 is movable to the material application position 206 aligned with the dispensing direction 204 to apply the paving material 228 to the laminating surface 120 while the first side 158 is moved to the material reload position 208 to service the first side 158 of the laminating head 152.

A7.A6, wherein: the lamination heads 152 are each configured to independently rotate at least 180 degrees about the vertical axis 174 to position either the first side 158 or the second side 160 of the lamination head 152 at the material application location 206 and to position the remaining one of the first side 158 and the second side 160 at the material reload location 208.

A8.A6 or A7, wherein the one or more lamination heads 152 comprise: a mounting frame 154 having a first side 158 and a second side 160; at least one head module 170 having a frame coupling element 172 that removably couples the head component 220 to one of the first side 158 and the second side 160 of the mounting frame 154; and the head module 170 is removable from the mounting frame 154 at the frame coupling elements 172 to allow replacement of the head module 170.

A9.A8, wherein the at least one lamination head 152 comprises: the first side 158 and the second side 160 each have a head module 170 removably coupled to the mounting frame 154; each head module 170 is vertically movable relative to the mounting frame 154; head module 170 on first side 158 may be locked in upper position 184 while head module 170 on second side 160 may be moved vertically to dispense paving material 228; and head module 170 on second side 160 may be locked in upper position 184 while head module 170 on first side 158 may be moved vertically to dispense paving material 228.

A10. The manufacturing system 100 of any one of a6 to A9, further comprising: a horizontal shaft 176 oriented parallel to the plurality of lamination heads 152; and each lamination head 152 can rotate at least 180 degrees about horizontal axis 176 to move first side 158 and second side 160 between material application position 206 and material reload position 208.

A manufacturing system 100 of any one of A1 to a10, further comprising: a reloading system 450 having a head transfer mechanism 452 and a reloading station 460; and the head transport mechanism 452 is configured to remove one of the lamination heads 152 from the lamination station 150, install a replacement lamination head 466 in place of the removed lamination head 468, and transport the removed lamination head 468 to the reload station 460.

The manufacturing system 100 of any one of A1 to a11, further comprising: a reloading system 450 having a head transfer mechanism 452 and a reloading station 460; at least one mounting frame 154; the lamination heads 152 are configured as head modules 170, the head modules 170 each including a frame coupling element 172 that removably couples the head component 220 to the mounting frame 154; at least one head module 170 is removable from the mounting frame 154 at the frame coupling elements 172 to allow replacement of the head module 170; and the head transfer mechanism 452 is configured to remove a selected one of the head modules 170 from the laminating station 150, install a replacement head module 170 in place of the removed head module 170, and transport the removed head module 170 to the reloading station 460.

A13. Any of the manufacturing systems 100 of A1 to a12, wherein the one or more lamination heads 152 comprise a head component 220, the head component 220 comprising: at least one material supply roll 222 configured to support a roll 224 of backing material 226, the backing material 226 comprising paving material 228 supported by a backing layer 230; at least one material dispensing mechanism 260 configured to receive backing material 226 from material supply roll 222 and separate backing layer 230 from paving material 228; and at least one backing layer collection roller 300 configured to take up backing layer 230 after separation from paving material 228.

B1. A manufacturing system 100 comprising: a series of laminating heads 152 stationarily positioned in end-to-end relationship with one another and defining a laminating station 150, each laminating head 152 within the series configured to dispense a paving material 228 along a dispensing direction 204; a lamination belt 124 having an outer surface movable in a direction generally aligned with the dispensing direction 204 below the lamination station 150, the lamination head 152 being configured to sequentially apply a paving material 228 onto the outer surface of the lamination belt 124 and onto the previously applied paving material 228 as the outer surface of the lamination belt 124 moves through the lamination station 150, thereby forming a stacked composite laminate 400 having composite plies 402 arranged in a desired ply stacking sequence defined by the positions of the lamination heads 152 relative to each other within the lamination station 150; and one or more finishing devices 312 located downstream of lamination station 150 and configured to periodically form transverse cuts 314 in composite laminate 400 to separate composite laminate 400 into longitudinal segments 401.

C1. A method of manufacturing a composite laminate 400, comprising: dispensing a paving material 228 in the dispensing direction 204 from one or more of a series of laminating heads 152, the series of laminating heads 152 being stationarily positioned in end-to-end relationship with one another and defining a laminating station 150; moving the laminating surface 120 between the laminating surface origin position 134 and the laminating surface back position 136 in a direction generally aligned with the dispensing direction 204 below the laminating station 150; applying a layup material 228 onto the lamination surface 120 and onto a previously applied layup material 228 from one or more lamination heads 152 as the lamination surface 120 passes through the lamination station 150, thereby forming a composite laminate 400 having a stack of composite plies 402 arranged in a desired ply stacking order, the lamination heads 152 being arranged within the series of lamination heads 152 to sequentially apply the layup material 228 according to the ply stacking order; trimming the composite laminate 400 using one or more trimming devices 312 during at least one of: during the movement of the lamination surface 120 from the lamination station 150 to the lamination surface home position 134; and during the movement of the lamination surface 120 from the lamination station 150 to the lamination surface rear position 136.

C2. The method of c1, further comprising: application of the paving material 228 by any one of the laminating heads 152 is independently started, stopped, or restarted at any location along the laminating surface 120 while continuing application of the paving material 228 by one or more other of the laminating heads 152.

C1 or C2, wherein the step of trimming the composite laminate 400: composite laminate 400 is trimmed using at least one of an ultrasonic blade, a laser device, or a mechanical cutter blade.

C1, C2 or C3, wherein the step of moving the lamination surface 120 below the lamination station 150 comprises: at least one continuous annular laminating belt 124 is moved under the laminating head 152 while applying the paving material 228 to the outer surface of the laminating belt 124 and the paving material 228 previously applied to the laminating belt 124.

C5.C1 to C4, wherein the steps of moving the laminating surface 120 below the laminating station 150 and applying the paving material 228 onto the laminating surface 120 comprise: at least one lamination mandrel 122 is translated in at least one direction under the lamination head 152 while applying the layup material 228 to the outer surface of the lamination mandrel 122 and to the layup material 228 previously applied to the lamination mandrel 122.

C6. C1-C5, wherein the steps of applying layup material 228 from one or more lamination heads 152 and trimming composite laminate 400 respectively comprise: continuously applying a layup material 228 from the laminating head 152 onto the laminating surface 120; at least one transverse cut 314 is formed in composite laminate 400 using one or more finishing devices 312 to separate composite laminate 400 into end-to-end longitudinal segments 401.

C1 to C6, further comprising: the composite laminate 400 is secured to the lamination surface 120 using vacuum pressure generated at the plurality of holes 144 formed in the lamination surface 120 and fluidly coupled to the vacuum pressure source 146.

C8.C5, wherein translating the lamination mandrel 122 in at least one direction under the lamination head 152 comprises one of: translating lamination mandrel 122 in a first direction of travel 128 from lamination surface origin position 134 through lamination station 150 and to lamination surface back position 136, subsequently translating lamination mandrel 122 in a second direction of travel 130 from lamination surface back position 136 through lamination station 150 and to lamination surface origin position 134, and applying layup material 228 to lamination surface 120 during translation in at least one of first direction of travel 128 and second direction of travel 130; translating the lamination mandrel 122 in a first direction of travel 128 from the lamination surface origin position 134 through the lamination station 150 and to the lamination surface back position 136, and applying a layup material 228 to the lamination surface 120 during the translation through the lamination station 150, and subsequently translating the lamination mandrel 122 from the lamination surface back position 136 to the lamination surface origin position 134 while bypassing the lamination station 150; and translating the lamination mandrel 122 from the lamination surface origin position 134 to the lamination surface back position 136 while bypassing the lamination station 150, then translating the lamination mandrel 122 in the second direction of travel 130 from the lamination surface back position 136 through the lamination station 150 and to the lamination surface origin position 134, and applying a layup material 228 to the lamination surface 120 during the translation through the lamination station 150.

C9. The method of any one of C1 to C8, wherein the lamination heads 152 each comprise laterally opposite sides including a first side 158 and a second side 160, the first side 158 and the second side 160 each having a head member 220, the method further comprising one of: moving the second side 160 to the material application position 206 aligned with the dispensing direction 204 to apply a paving material 228 to the laminating surface 120 while moving the first side 158 to the material reload position 208 to replace the roll of material 224 on the first side 158; and moving the first side 158 to the material application position 206 aligned with the dispensing direction 204 to apply the paving material 228 to the laminating surface 120 while moving the second side 160 to the material reload position 208 to replace the roll of material 224 on the second side 160.

C10.C9, wherein moving the second side 160 to the material application location 206 while moving the first side 158 to the material reload location 20 and moving the first side 158 to the material application location 206 while moving the second side 160 to the material reload location 208 comprises: the lamination heads 152 are independently rotated at least 180 degrees about the vertical axis 174 to position either the first side 158 or the second side 160 of the lamination head 152 at the material application location 206 and the remaining one of the first side 158 and the second side 160 at the material reload location 208.

C11.C10, wherein the at least one lamination head 152 comprises a mounting frame 154, the mounting frame 154 having a first side 158 and a second side 160 and comprising a head module 170 coupled to the first side 158 and a head module 170 coupled to the second side 160, the method further comprising: head module 170 on one of first side 158 or second side 160 is serviced while paving material 228 is dispensed from head module 170 on the remaining one of first side 158 or second side 160.

C12.C11, wherein the head module 170 on each of the first side 158 and the second side 160 is vertically movably coupled to the mounting frame 154, the method further comprising: allowing head module 170 on one of first side 158 and second side 160 to move vertically in unison with starting and stopping dispensing of paving material 228; and preventing vertical movement of the head module 170 on the remaining one of the first side 158 and the second side 160 to allow for servicing of the head module 170.

C13. The method of any one of C9 to C12, wherein moving the second side 160 to the material application position 206 while moving the first side 158 to the material reload position 208 and moving the first side 158 to the material application position 206 while moving the second side 160 to the material reload position 208 comprises: the laminating head 152 is rotated at least 180 degrees about a horizontal axis 176 oriented parallel to the series of laminating heads 152 to move the first side 158 and the second side 160 between the material application position 206 and the material reload position 208.

The method of any one of C1 to C13, further comprising: removing one of the lamination heads 152 from the lamination station 150 using the head transport mechanism 452 of the reload system 450; installing a replacement lamination head 466 in place of the lamination head 468 removed from the lamination station 150; transporting the removed lamination head 468 to the reload station 460 for at least one of: replace the roll of material 224 on the removed lamination head 468; and maintenance on the removed lamination head 468.

Additional modifications and improvements of the present disclosure will be apparent to those of ordinary skill in the art. Accordingly, the particular combination of parts described and illustrated herein is intended to represent only certain embodiments of the present disclosure, and is not intended to serve as limitations of alternative embodiments or devices within the spirit and scope of the present disclosure.

Claims

1.A manufacturing system (100), the manufacturing system (100) comprising:

a plurality of laminating heads (152), the plurality of laminating heads (152) stationarily positioned in end-to-end relationship with one another and defining a laminating station (150), each laminating head (152) configured to dispense a paving material (228) along a dispensing direction (204);

a lamination surface (120), the lamination surface (120) movable between a lamination surface home position (134) and a lamination surface aft position (136) in a direction generally aligned with the dispensing direction (204) below the lamination station (150), the lamination head (152) configured to sequentially apply the layup material (228) onto the lamination surface (120) and onto a previously applied layup material (228) as the lamination surface (120) passes through the lamination station (150) to form a composite laminate (400) having a stack of composite plies (402) arranged in a desired ply stack sequence defined by the positions of the lamination heads (152) relative to each other within the lamination station (150);

one or more finishing devices (312), the one or more finishing devices (312) located proximate to at least one of the opposing ends of the lamination station (150) and configured to finish the composite laminate (400) during at least one of:

during the movement of the lamination surface (120) from the lamination station (150) to the lamination surface home position (134); and

the lamination surface (120) is moved from the lamination station (150) to the lamination surface back position (136).

2. The manufacturing system (100) of claim 1, wherein the lamination surface (120) comprises one of:

an outer surface of at least one continuous annular laminating belt (124), the at least one continuous annular laminating belt (124) being movable under the laminating head (152); and

an outer surface of at least one rigid lamination mandrel (122), the at least one rigid lamination mandrel (122) being translatable under the lamination head (152).

3. The manufacturing system (100) of claim 2, wherein:

the lamination head (152) is configured to continuously dispense a layup material (228) onto the outer surface of the lamination surface (120); and

the one or more trimming devices (312) are configured to periodically cut the composite laminate (400) in a cross direction to divide the composite laminate (400) into end-to-end longitudinal segments (401).

4. The manufacturing system (100) of claim 2, the manufacturing system (100) further comprising:

a vacuum pressure source (146);

the lamination surface (120) having a plurality of apertures (144) fluidly coupled to the vacuum pressure source (146); and is

The vacuum pressure source (146) is configured to generate vacuum pressure at the outer surface to secure the composite laminate (400) to the outer surface at least during application of paving material (228) onto the outer surface or onto paving material (228) previously applied to the outer surface.

5. The manufacturing system (100) of claim 1 or 2, wherein:

the lamination heads (152) each include laterally opposite sides including a first side (158) and a second side (160), the first side (158) and the second side (160) each having a head component (220); and is

The first side (158) of at least one of the lamination heads (152) is movable to a material application position (206) aligned with the dispensing direction (204) to apply a layup material (228) to the lamination surface (120) while the second side (160) is moved to a material reload position (208) to service the second side (160) of the lamination head (152); and is

The second side (160) is movable to the material application position (206) aligned with the dispensing direction (204) to apply a paving material (228) to the laminating surface (120) while the first side (158) is moved to the material reload position (208) to service the first side (158) of the laminating head (152).

6. The manufacturing system (100) of claim 1 or 2, the manufacturing system (100) further comprising:

a reloading system (450) having a head transfer mechanism (452) and a reloading station (460); and is provided with

The head transport mechanism (452) is configured to remove one of the lamination heads (152) from the lamination station (150), install a replacement lamination head (466) in place of the removed lamination head (468), and transport the removed lamination head (468) to the reload station (460).

7. The manufacturing system (100) of claim 1 or 2, the manufacturing system (100) further comprising:

a reloading system (450) having a head transfer mechanism (452) and a reloading station (460);

at least one mounting frame (154);

the lamination heads (152) are configured as head modules (170), the head modules (170) each comprising a frame coupling element (172) that removably couples a head component (220) to the mounting frame (154);

at least one of the head modules (170) is removable from the mounting frame (154) at the frame coupling element (172) to allow replacement of the head module (170); and is provided with

The head transport mechanism (452) is configured to remove a selected one of the head modules (170) from the laminating station (150), install a replacement head module (170) in place of the removed head module (170), and transport the removed head module (170) to the reload station (460).

8. The manufacturing system (100) of claim 1 or 2, wherein one or more of the lamination heads (152) comprises a head component (220), the head component (220) comprising:

at least one material supply drum (222), the at least one material supply drum (222) configured to support a roll (224) of backing material (226), the backing material (226) comprising a paving material (228) supported by a backing layer (230);

at least one material dispensing mechanism (260), the at least one material dispensing mechanism (260) configured to receive the backing material (226) from the material supply roll (222) and separate the backing layer (230) from the paving material (228); and

at least one backing layer collection roller (300), the at least one backing layer collection roller (300) configured to take up the backing layer (230) after separation from the paving material (228).

9.A method of manufacturing a composite laminate (400), the method comprising:

dispensing a paving material (228) in a dispensing direction (204) from one or more of a series of laminating heads (152), the series of laminating heads (152) being stationarily positioned in end-to-end relationship with one another and defining a laminating station (150);

moving a lamination surface (120) between a lamination surface home position (134) and a lamination surface back position (136) in a direction generally aligned with the dispensing direction (204) below the lamination station (150);

applying the layup material (228) from one or more of the lamination heads (152) onto the lamination surface (120) and onto previously applied layup material (228) as the lamination surface (120) passes through the lamination station (150) to form a composite laminate (400) having a stack of composite plies (402) arranged in a desired ply stacking order, the lamination heads (152) being arranged within the series of lamination heads (152) to sequentially apply layup material (228) according to the ply stacking order;

trimming the composite laminate (400) using one or more trimming devices (312) during at least one of:

the lamination surface (120) is moved from the lamination station (150) to the lamination surface rear position (136).

10. The method of claim 9, further comprising:

independently starting, stopping or restarting application of a layup material (228) by any one of the lamination heads (152) at any location along the lamination surface (120) while continuing application of a layup material (228) by one or more other of the lamination heads (152).

11. The method according to claim 9 or 10, wherein the step of moving the lamination surface (120) under the lamination station (150) comprises:

moving at least one continuous annular laminating belt (124) under the laminating head (152) while applying a paving material (228) to the outer surface of the laminating belt (124) and to a paving material (228) previously applied to the laminating belt (124).

12. The method of claim 9 or 10, wherein the steps of moving the laminating surface (120) under the laminating station (150) and applying the paving material (228) onto the laminating surface (120) comprise:

translating at least one lamination mandrel (122) in at least one direction under the lamination head (152) while applying a layup material (228) onto the outer surface of the lamination mandrel (122) and a layup material (228) previously applied onto the lamination mandrel (122).

13. The method of claim 9 or 10, wherein the steps of applying the layup material (228) from one or more of the lamination heads (152) and trimming the composite laminate (400) respectively comprise:

continuously applying the layup material (228) from the lamination head (152) onto the lamination surface (120);

forming at least one transverse cut (314) in the composite laminate (400) using the one or more finishing devices (312) to divide the composite laminate (400) into end-to-end longitudinal segments (401).

14. The method of claim 9 or 10, further comprising:

securing the composite laminate (400) to the lamination surface (120) using vacuum pressure generated at a plurality of holes (144) formed in the lamination surface (120) and fluidly coupled to a vacuum pressure source (146).

15. The method of claim 9 or 10, further comprising:

removing one of the lamination heads (152) from the lamination station (150) using a head transport mechanism (452) of a reload system (450);

installing a replacement lamination head (466) in place of the lamination head (468) removed from the lamination station (150);

transporting the removed lamination head (468) to a reload station (460) for at least one of:

replacing the roll of material (224) on the removed lamination head (468); and

maintenance is performed on the removed lamination head (468).